It is interesting to learn the bottom of the sheets. They were made of a flat fabric that covered the mattress. It was usually a rectangular roll cloth with no center seam. Today, they have hems at the top and bottom of the sheet. The finished edges of the loomed sheet are used as side seams so it is not necessary to fold the sides. The sheet is part of a set consisting of a bottom sheet, top sheet and pillowcase.
Sheets can be made from a variety of materials including linen, cotton, and synthetic materials, which are usually natural fibers such as cotton, and sometimes silk. Another popular fabric used is percale, which can be a cotton or polyester blend that is soft and cool on the skin. Another fabric is muslin, which is slightly harder than cotton. During the winter months, flannel sheets made from a cotton diaper-like material will keep you warm. There are also silky satin sheets that are quite expensive. Linen sheets are imported from Eastern Europe and are sometimes used commercially in the best hotels, but are not available in this country as they are not processed here in the United States.
Linen was probably the first material used and is made from the flax plant which has been cultivated for centuries and spun and woven by the Egyptians. It’s a laborious procedure to grow, but when finished, it’s perfect for bedding.
Europe brought flax to the New World and it flourished in the northeast and central colonies for 200 years. Growing flax is a long process. Throughout the 17th through the 19th centuries, American women worked tirelessly making pillowcases, sheets, napkins, and towels for their families.
Around 1830 in the United States, cotton processing was a growth industry. It was difficult to remove the seeds from cotton bales until Eli Whitney invented the cotton gin, thus eliminating manual labor. Plantations in the south began to grow, and as a result, slave labor was used to plant and pick the cotton. Around this same period, New England textile mills were using British cotton techniques, allowing them to be spun, weaved, and dyed in enormous quantities. Cotton fibers were made from bales of raw cotton that was processed to prepare it for spinning. Once loaded onto a section beam, they were spun into bobbins which were primed, making weaving much easier. The looms automatically tie the old thread with a machine called a knotter. Looms were mechanized so that human hands barely touched the fiber. The sheets have been made on looms since the end of the 19th century.
Sheet manufacturers carefully collect cotton bales. Cotton bales are sorted by length and quality. The short fibers are used for batting, while the long fibers are used for higher quality products. Egyptian cotton is noted for the longer fiber. Medium fiber is considered medium grade. Surprisingly, there are 9 grades of cotton. Lower grade bales will never produce a quality product.
Next it was necessary to clean the cloth since it was gray in color. It was finished with bits of thread that were burned to the surface. The sheet is then ready to be bleached. First, it is bathed in soap and water which removes contaminants. Followed by caustic chemicals that are applied to remove any dirt and debris left on the cotton thread. The caustic solution is washed and bleaches are applied to dissipate the gray color. Once bleached, the sheet will be rolled onto a rope and placed in a dryer that removes moisture before dyeing. Automatic cutting equipment cuts the rolls into standard sheet lengths and then the hems are sewn.
Today, the material is a blended fiber of cotton and polyester that keeps sheets wrinkle-free. Also, the colors and design patterns are quite popular.
Currently, Georgia is the state with the largest number of cotton processors and weavers in the entire country. Since labor is cheaper outside of the United States, many of our sheets are made in other countries and imported here. The South is the producer of most of the American cotton sheets.
A great deal of effort has now been made to reduce cotton fiber contamination. In the past, cotton fiber was dangerous for factory workers. Today, we have air-jet looms that generate very little cotton fiber. The Federal Government now has regulations in place to control caustic liquids from contaminating the environment and plants must have a permit from the national discharge system. Emissions are now controlled by the Clean Air Act and must meet acceptable guidelines.