Frequently Asked Questions
Q: What is the difference between circular knitting and flat knitting for garments?
A: Circular knitting produces a seamless tubular fabric on a cylinder of needles rotating continuously — the output is a fabric tube. Flat knitting uses two opposing needle beds moving back and forth to produce flat fabric panels, which can also be shaped (fully fashioned) during knitting. Circular knitting is faster and more cost-effective for high-volume T-shirts, sweatshirts, and bed sheets. Flat knitting is used for shaped knitwear, collars, cuffs, and technical pieces where shaping during knitting adds value.
Q: Why do most T-shirts and bed sheets use circular knitting rather than flat knitting?
A: Circular knitting machines run continuously without stopping to reverse direction, making them significantly faster than flat knitting machines — a large-diameter circular machine can produce 40–60 kg of fabric per shift versus 5–15 kg for flat knitting. For commodity products like T-shirts and sheets where the fabric is cut and sewn anyway, seamlessness offers no garment-level advantage, so the speed and cost efficiency of circular knitting wins every time.
Q: What is “gauge” in circular knitting, and how does it affect my product?
A: Gauge refers to the number of needles per inch on the knitting machine cylinder. Higher gauge (28G, 32G) = finer, smoother fabric suitable for lightweight T-shirts and fine jersey. Lower gauge (18G, 22G) = coarser, thicker fabric suitable for fleece, sweatshirts, and heavier-weight products. Gauge must match the yarn count specified — mismatching causes knitting defects and inconsistent GSM.
Q: Can circular knitting produce patterns and designs, or is it only plain fabric?
A: Modern electronic circular knitting machines can produce jacquard patterns, stripes, ribbing, mesh, and textured effects by controlling individual needles selectively. Al Madni Textiles produces jacquard knit fabric and structured textures in addition to plain jersey and fleece. Complex multi-colour jacquard requires specialised machines and higher setup costs, so it’s better suited for larger orders where the setup cost amortises effectively.
Q: What fabric widths does circular knitting produce, and how does that affect cutting waste?
A: The fabric tube width depends on the cylinder diameter. Fabric is cut open and spread flat for cutting, giving a flat width of approximately π × cylinder diameter. Common usable widths range from 140 cm to 210 cm for wide-width machines used for bed sheets and home textiles. Wider fabric reduces seams in panels and decreases cutting waste — important for large flat products like fitted sheets where a wider width means fewer joins.
Q: Is circular-knit fabric always stretchier than woven fabric?
A: Yes, due to its loop structure — circular knit fabric stretches in both directions (two-way stretch), and four-way stretch can be added with elastane/spandex in the yarn. Woven fabric has minimal stretch (5–10% on the bias at best) because the interlocked warp and weft threads resist deformation. For fitted sheets, T-shirts, and activewear, this stretch is a feature. For structured workwear or suiting, it’s why woven fabric is preferred for those categories.