What Is Cotton Fabric? Ultimate Guide to Nature’s Perfect Material

Cotton is the KING of the textile industry. No one will argue with this.

It’s versatile, perfect for clothing, and is straight-up a NEED for the fashion industry.

But guess what—many startups FAIL to tap into cotton’s true power. They see cotton fabric as a one-and-done material. Not realizing that you gotta focus on the types, treatments, and packaging to make the most of it.

We’re a private label manufacturer. So we work with cotton daily. Millions of manufactured cotton pieces later, we’ve consolidated all our cotton know-how. 

No filters. No fillers. Here’s your COMPLETE cotton fabric guide. 

Take a leap toward creating cotton products that are TEN TIMES better!

What is Cotton Fabric?

Cotton is a natural, plant-based fiber staple in the fashion industry. It’s everywhere you look. And everywhere, it sells. It’s one of the BEST-SELLING sustainable fabric materials.

But hey—this material isn’t just for fashion. It’s also used in medical and industrial applications due to its versatility.

As a business owner, choosing cotton signals eco-friendliness and is TRUSTED by customers. People see cotton and instantly, they think comfort and quality. It holds dye well, doesn’t irritate, and breathes naturally.

Cotton can be used on its own or blended with other synthetic fibers. It really depends on what you’re going for.

It’s almost impossible to create a clothing brand without a touch of cotton in the mix. So, MAKE SURE your cotton is fully utilized to your favor.

The Process of Making Cotton Fabric 

The start of fabric making is literally the cotton plant. They look like white balls (called bolls, by the way). And the fluff that surrounds the seeds is what’s needed to create fabric. 

First, it starts with the harvesting phase. Back in the day, farmers would do this by hand. But today, we have machines to do this process.

Next, the ginning process starts. The seeds, debris, and dirt are filtered. So only the good stuff remains! The fluffy cotton fiber. 

By this point, though, that fiber is still nothing but fluff.

Fluff that must be turned into yarn. To do that, a process called carding is done. That’s when the fibers are combed and turned into long strands. After that, the strands are SPUN (spinning process). 

And now, you have white cotton yarn! Is it ready for weaving? Well, a bit. But not quite. 

From here on, the fibers need to be carefully dyed and treated before they can be turned into fabric. After it’s woven in varying techniques (talk about this later). That’s when it truly becomes usable cotton fabric.

Where does cotton grow, you ask?

Mostly in warm climates. The United States, China, Uzbekistan, and India are leading cotton suppliers. That’s where jeans companies get their fabric mainly.

Top Cotton Properties

Cotton wouldn’t be everyone’s go-to fabric if it didn’t have TONS of exceptional qualities. Let’s uncover FIVE. Properties that matter if you want to start a fashion brand. 

Soft & Comfortable

Wearing cotton feels like a hug. Soft. Gentle. The type you’ll say YES to anytime. That’s why it’s popular for everyday tees. As well as COZY blankets. Very few fabrics can match its level of comfort.

Pro tip: You can highlight comfort in marketing. Customers notice softness before price. It’s a quick way to justify premium pricing.

Odor resistant

Cotton’s odor-resistant. So it’ll still impress your customers even on sweaty days. The sweat spreads out and dries FAST. No buildup. That’s why for items like socks and underwear, cotton is the go-to choice. 

But hey, cotton is for light sweating. Not for sportswear types. For those, you want moisture-wicking synthetic materials. The most beloved fabrics for wholesale gym manufacturers.

Selling advice: Try to sell cotton basics in bundles. Sell socks or underwear in sets of three rather than single pieces. Make buying more convenient for customers. And increase your chances of selling more products at the same time. 

Breathable

I haven’t seen anyone who HATES breathable clothes. They let air pass through. Less overheating and more comfort. Customers definitely notice this, especially during summer days. 

This is the BIGGEST perk of cotton. When you compare cotton vs polyester hoodies, for example.

Sustainable

100% cotton is a 100% natural fiber. It’s plant-based and biodegradable. That means it’s popular among young people who prefer to save the planet.

Durable

Yes—it’s soft. But don’t let that FOOL you. It can handle a fair amount of roughness. Frequent washing and regular wear are no-brainers. But heads up, cotton is infamous for occasional wrinkles, which brings us to the next section.

The Potential Cons of Cotton Fabric

No fabric is PERFECT. So while cotton is everyone’s beloved staple, it also has cons. Don’t worry—nothing too crazy.

Pricier than Synthetic Fibers

You probably already know this. But cotton is pricier than synthetics. Cotton costs more to grow, harvest, and process after all. You need more land, water, fertilizer—lots of costs associated with farming itself. Then, of course, there’s production time and labor (or machinery) expenses.

Synthetic fibers are more straightforward.

They come from petroleum or chemicals. The process sticks to the formula. Scaling is EXTRA easy too. There’s no waiting for the cotton plant to grow for you to harvest it, which is why some European clothing manufacturers incorporate synthetics to meet fast fashion demands and large-scale production needs.

Pro tip: Cotton has different tiers, too. Regular cotton is pricier than polyester but still cheaper than premium options. Organic cotton, Egyptian cotton, and Supima are examples of high-end cotton.

Shrinking Problems 

Unfortunately, cotton loves to shrink when washed and dried. After the first wash, that “M” you sold could be more like an “S.” Not great. Because that means frustrated customers and possible returns. And yeah, a couple of bad reviews.

But there’s a FIX—manufacturers pre-shrink the fabric. That way, your customers experience no surprise sizing issues.

Cotton Fiber Varieties

Not every cotton has the same value. You have to look at the cotton fiber used and how the cotton fabric is built. First, let’s go over the most popular cotton fiber varieties. Then, we’ll jump straight to the construction types! 

6 Most Popular Cotton Fabric Types

Here’s a rookie brand mistake. Just asking the manufacturer to use “cotton.” Well, that phrase can mean a dozen different things. Manufacturers can get away with sending the wrong type. All because you weren’t specific enough.

As a brand owner, you MUST know your cotton fabric types, too. Don’t want to get fooled. Manufacture exactly what you envision.

Plain Weave Cotton

Meet the OG cotton fabric types—plain weave fabric. It’s the MOST basic and standard. But don’t think it’s boring. It works. The simple over-and-under weave pattern makes it ideal for lightweight and breathable clothing. This fabric is perfect for casual tees, bedding, and sheets.

Manufacturer’s advice: Use plain weave cotton for high-volume products. It’s cheap, versatile, and easy to brand. You’ll maximize profit margins for basics like tees and sheets.

Twill Cotton

Up close, twill shows a diagonal texture, not over-and-under like plain weave. This one’s tougher than plain weave. It’s built for action, kinda fabric. So, it’s perfect for chinos, workwear, and denim. I’m sure you know that those garments aren’t exactly too comfortable, right? But they’re sturdy!

Denim twill fabric is a classic example of this fabric type. 

Flannel Cotton

Flannel cotton has a BRUSHED surface. It’s kinda soft with a fuzzy texture. Think pajamas, winter shirts, and thick bedding. It’s like cotton’s attempt to be like wool. In your brand, you can use this fabric for cozy shirts, warm pajamas, and blankets. Clothing lines that focus on comfort will love it.

Jersey Cotton

Jersey cotton has a web-like knit that’s comfy and stretchy. Up close, it looks like a knitted sweater. But since the knit is so fine, it can look like smooth fabric from a distance. This one’s perfect for loungewear, everyday wear, and even dresses.

Cotton Lawn

Lightweight, finely woven, and crisp-smooth. Cotton lawn is like LINEN-LITE. It has that polished finish. Perfect for chic blouses, breezy dresses, or classy nightwear. It’s cotton that looks a little more “upscale” without being fussy.

Cotton Voile

This one’s woven with high-twist cotton yarns. So the results are impressive. Semi-sheer, airy, and soft to the touch. This fabric drapes lightly. No wonder it’s perfect for flowy summer dresses, breezy tops, or delicate curtains.

Suggested Reading:

10 Top China Leggings Manufacturers That Will Blow Your Mind

Top 10 Sportswear Manufacturers in China Deliver Unbeatable Value

Common Uses of Cotton Fabric

Is Cotton Fabric Expensive?

This may surprise you. But cotton is actually among the LEAST EXPENSIVE textile fibers. Yes—it’s more costly than synthetic fibers. But it’s still cheaper than silk or wool.

Obviously, the exact price can vary depending on factors.

Made in the US? Cotton is pricier. China-made, it’s always gonna be cheaper. Chinese manufacturers save on raw materials, labor, and production costs.

Want to launch a luxurious cotton line?

Opt for extra-long-staple cotton like Egyptian cotton and Pima cotton. They cost more to produce. But you’ll get what you pay for, as the results are soft and durable.

Our advice: If opting for PREMIUM cotton, market heavily. Highlight the fabric’s difference from regular cotton. Create a luxury perception that justifies the price. Not everyone knows the VALUE of these cotton types. So you have to introduce the concept. 

Bhavesh M., Textile Sourcing Head

Cotton’s Environmental Impact and Certifications

Cotton isn’t always eco-friendly or sustainable. See, certain plants or farms don’t follow best practices. They may use chemicals or unsustainable practices during growing or while processing.

That’s why you should ask manufacturers for certifications. Make sure they verify that the cotton is ORGANIC. In the US, the United States Department of Agriculture (USDA) offers certifications.

But on a global level, OEKO-TEX provides certifications, too.

Want to make Supima (premium) clothes? Make sure your clothes are American Supima Association (ASA) certified. Without certifications, no authentic Pima.

Getting Cotton Customer-Ready: Business Owner Tips

Cotton care tips are one thing. Business owner tips for making the BEST cotton clothing are another! 

Choose the Right Type 

The types mentioned above aren’t just for fun facts. They’ll literally influence how your clothes look and feel. Denim twill is perfect for jeans. But don’t exactly use it for a summer dress. Plain weave is ideal for regular t-shirt, too dull for dresses or flowy tops.

Choose the right type carefully to impress customers. Quality fabric selection is crucial, which is why many successful brands partner with experienced Jeans Manufacturers in China who understand how different cotton fabrics perform in various garment applications.

Pre-Shrink Before Production 

As mentioned, cotton LOVES to shrink. Unless you pre-shrink. The more technical term is sanforize. Ensure your clothing manufacturer properly implements it. If in doubt, request a sample and wash it yourself.

Add Proper Finishing 

Raw cotton can wrinkle like crazy. That’s why manufacturers often apply finishing treatments—like anti-wrinkle, moisture-wicking, and softener. These are upgrades that customers won’t really know. But they’ll notice the difference in their experience in the long run.

Packaging Matters

Cotton CREASES. And you don’t want customers to receive creased clothes. That said, use packaging that works for your clothes. Use tissue, roll garments, or boxes to keep them looking fresh. You want them to appear as if they came straight from dry cleaning—crisp and perfect.

First impression matters. Inside and out, the packaging. So you GOT to know how to package clothing for shipping like a PRO.

Business tip: Include a small care guide in your packaging. This helps customers maintain garments longer, increasing brand loyalty.

People Also Ask About Cotton Fabric

Conclusion

By now, it wouldn’t be an exaggeration to call you a cotton master. Everything here is ready to LEVERAGE for your business. Serve the comfiest clothes and happy customers. And protect your business with certifications and trusted suppliers.

Need a manufacturer that can customize fully certified cotton?

Contact JaceApparel, the best CUSTOM manufacturer in China. From t-shirts, dresses, and jeans—we can handle all your cotton needs. LOWEST prices guaranteed. Message or email us for a free quotation. No strings attached! 

Source:

1. History of cottons – www.masterclass.com 
2. Cotton certifications –  www.thecottonlondon.com