Classification of Woven Labels
Cut-edge Woven Labels
These are produced using West German machinery. As the name implies, the labels are woven as a continuous roll on specialized high-speed machines and then cut into strips according to the desired width. Due to the heat-melting properties of polyester, the yarns fuse together during the cutting process, preventing the edges from fraying. However, this process does affect the label's appearance and texture; higher-quality machines yield better results, and ultrasonic cutting produces a superior finish compared to standard thermal cutting. The resulting strip-form labels can be sent directly to garment factories for processing, though strict specifications may require additional cutting and folding steps. Since the machine has a maximum weaving width of 20.8 cm, labels can be produced in this width and subsequently cut into various shapes.
Based on the manufacturing process, they are categorized into two main types: plain weave labels and satin weave labels.
Plain Weave Labels
These labels feature a simple weave structure where warp and weft yarns interlace over and under one another. Generally, the warp yarns are fixed in color-either black or white-resulting in "black-warp plain" and "white-warp plain" varieties; white-warp is typically used for light-colored backgrounds, while black-warp is used for dark ones. The label's patterns and colors are primarily rendered through the weft yarns, with the final color appearance influenced by the specific way the weft intersects with the warp. As machines typically limit the number of weft yarn types that can be used, the color palette is also restricted-usually to a maximum of eight colors. Consequently, pricing factors include the label width (determining the amount of warp yarn used), the label length, and the length of each color along the warp direction. To achieve richer detail and color, the weft yarns can be doubled, creating a "double-weft" label; if a specific color requires a more three-dimensional effect, an extra layer of yarn is added, a technique known as "heavy-weft" (or multi-pick) weaving. Aside from care and size labels, most labels utilize the plain double-weft style. Since patterns are created using yarn, there will inevitably be differences from the original graphic design; therefore, mass production cannot proceed without first producing and approving a sample.
Satin Weave Labels
These are also formed by the interlacing of warp and weft yarns. In addition to improving quality by doubling the weft yarns, quality can also be enhanced by doubling the warp yarns-a process that creates the satin weave structure. Doubling the warp yarns results in a softer, smoother texture for the woven label. However, the resulting high density hinders the weft yarns from clearly defining the pattern and limits flexibility in background color rendering; specific color requirements must often be achieved through post-processing. Machine settings for producing either plain weave or satin weave are generally fixed. The width of cut-edge satin labels typically does not exceed 10.8 cm, while woven-edge labels generally do not exceed 5.0 cm.