Rêveur Linen


How Cotton is Made




Cotton production is a complex, multi-step process that starts in the field and ends with the finished product, such as bed linen. The process can vary slightly depending on factors like the grade of cotton (e.g., Egyptian or Pima cotton) and the type of finish desired for the final product. Below is a breakdown of the journey from farming cotton to producing bed linen:

1. Farming and Harvesting

Cotton seeds are sown in well-prepared soil in regions with warm climates, like the southern United States, India, or China. It typically takes 5-6 months for the plants to mature. As the cotton plants grow, they develop fluffy white bolls, which contain the cotton fibers. Once the cotton bolls open, they are ready to be harvested. This is done either manually or using mechanical cotton pickers.

2. Ginning

The raw cotton picked from the field contains seeds, dirt, and other debris. Ginning is the process of removing these impurities. A cotton gin machine separates the cotton fibers from the seeds and other plant material. The fibers are cleaned and prepared for the next stages, while the seeds are used for animal feed, oil, or replanting.

3. Spinning

After ginning, the clean cotton fibers are compressed into bales for transport to textile mills. At the textile mill, the cotton is carded, where the fibers are untangled and aligned to create a continuous web of cotton. The aligned fibers are then drawn out and twisted to form yarn. This yarn can vary in thickness and quality depending on the desired final fabric.

4. Weaving or Knitting

The cotton yarn is woven into fabric on looms. Most bed linen fabrics are woven using a plain or sateen weave, depending on the desired texture and strength. In some cases, cotton can be knitted into fabric, though woven cotton is more common for bedding.

5. Dyeing and Finishing

The cotton fabric is dyed in various colors, patterns, or left in its natural state depending on the product's design. Reactive dyes are often used for cotton as they provide rich, long-lasting colours. Finishing processes such as bleaching, softening, and mercerizing (for added strength and shine) are applied to improve the fabric’s appearance, softness, and durability.

6. Cutting, Sewing, Stitching and Fitting

The fabric is cut into pieces of the required sizes for bed linens such as sheets, pillowcases, and duvet covers. Skilled workers or automated machines sew the pieces together to create the final product, ensuring proper hems, edges, and closures like buttons or zippers.

7. Uniquely Rêveur

All Réveur hotel bed linen is produced using quality imported percale fabrics (mostly cotton) in authentic 200 thread count, and up to the ultra-luxurious 800 thread count, depending on the customer’s own requirements. Read more about cotton production in South Africa here.






Rêveur Linen Collection

Our hotel bed linen range includes custom duvet covers and inners, fitted bed sheets, flat sheets, pillowcases and inners, and mattress protectors.

Duvet & Pillow Inners (2)
Duvet Covers (4)
Fitted Sheets (2)
Flat Sheets (2)
Mattress Converters & Protectors (3)
Pillow Protectors (2)
Pillowcases (2)
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