Weaving is the stage of creating the fabric by weaving warp threads with weft threads. All COGAL® looms are air-jet electronic: this means that in the working process the weft yarn is introduced into the warp with an air flow, to guarantee a much smoother fabric thanks to the millesimal position control of electronic control units. In terms of product innovation, COGAL® has introduced, in the production of terry towels, a special yarn: the American cotton cotton usa® which has superior yarn performance in terms of water absorption, due to to the air increased inside the wire itself. Using the microscope it is clearly visible that the fibers have a more irregular position and have more space between them: this is the secret of the exceptional performances of COGAL® towels. The weaving technique, the choice of the right type of yarn and the subsequent finishing stages of the fabric, are the key to the production of the best fabrics in the world.

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Usually, at the weaving stage, the dyeing process follows, in which there is a high use of water for the whole processing time. Being on saving and recycling means, first of all, reduce every resource consumption. Among the most important goals achieved in the last 20 years, COGAL® considers the investment made for energy saving. COGAL® has worked to develop a specific machine to reduce the consumption of liters of water per kilogram of product: from 12 l / kg to only 6 l / kg. This innovation led to savings equivalent to 50% of the energy cost and 50% of the water need; of course, the advantage also benefits the following phases since the amount of water that must be cleaned after the operations is reduced. Thanks to this machine, which works with an unconventional dye, different from the most common on the market, COGAL® has had an impact both on saving resources and on improving the product features. This new process has led to new goals for the volume of absorbed water in the sponge, a lower stress of the fibers during processing and therefore greater longevity of the product. COGAL® has also developed a custom drying unit that uses in the finish of the fabric surface to give maximum volume and softness.

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COGAL®'s attention to energy saving also emerges from the installation of a solar cell system, in 2010: a total power of 600 kW was obtained on 4,500 m2 of roofing, sufficient to supply all the energy consumption of the factory, saving fossil resources and making an important contribution to the fight against enviroment pollution. From the time of the installation until the end of 2017, 3,725,657 kWh were produced, which made "saving" an equivalent of 2,487,692 tons of CO2 and 16,290 trees. The mission of COGAL® is to continue in this direction, seeking continuous production improvement and, at the same time, environmental sustainability by investing in the modernization of plants and using more and more clean energy.

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