Journey2textile

Package Dyeing or sometimes called yarn dyeing, is when the yarn is wound on dye tubes as packages, each with a hollow center that allows liquid to flow through it. The packages are stacked on perforated, hollow posts, and dye liquor is pumped through these. Package machines are enclosed and can be pressurized so dye liquor can reach temperatures above atmospheric boiling point (100 C) for faster dyeing. The term yarn-dyed is associated with quality in woven fabrics. A pattern with dyed yarns looks sharper than one printed. The fabric will probably be more colorfast. The yarn dyeing process takes place between spinning and weaving steps.

Earlier we discussed jacquard weaving. As most of the Jacquard towel sold in the US are for beach towels almost all of these are made with yarns dyed before weaving. In addition, all stripe towels are made with package dyed yarns.
Yarn dyeing is more expensive for several reasons, one, the size of the dye vessels is limited therefore you have to dye a certain number of KG's of a single color. If you do not use all of this color during the weaving process, the wasted yarns is pretty much useless. Two, yarn dying take much more time than piece dyeing, so it takes longer to build the product. Three, if the towel does not come off the loom perfect, there is no way to fix the problem and the towel becomes a second or third quality instantly. With a Greige towel, you can go back and fix the color, but with a Yarn dyed towel you can never change the color after dyeing. Four, a towel mill through experience has a good idea as to how many seconds will be woven in the normal production. So if they plan on 10% seconds in production and were planning to make 4,000 towels, they would actually produce 4,400 towels. If the towel is a dobby solid color towel and they need to make more, then it is pretty easy to beam up a dobby loom and make a few more to complete an order. But with a Yarn Dyed jacquard towel they would have to go all the way back to the beginning of the process and take the Single Packages and dye them. Remember the size of the dye vessels, yes, they would have to dye hundreds of pounds of each color just to make 400 towels. This process can take 2-3 weeks of time and they would have to throw away hundreds of pounds of wasted yarns.
Yarn Dyed towels cost more because they create waste for the factory. They would still have to pay for the chemicals to dye, pay the labor to dye, and cover the overhead of the production, just to make a few additional products to complete the order. All of the profit from the order would be lost.