What is Modal Fabric and How is it Made?

Modal fabric is a type of luxurious, semi-synthetic fabric that is derived from beech tree pulp and is primarily used by textile manufacturers for clothing and household items. In this article, we’ll discuss the production and manufacturing process, properties, and benefits of modal fabric.

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What Fabric is Modal?

Modal fabric is a type of semi-synthetic fabric that is made from beech tree pulp. It is a form of rayon, which is another plant-based textile, but it is more durable and flexible than other rayon fabrics.

Modal is known for its stretchy, breathable, and lightweight nature. It is often blended with other fibers like cotton and spandex for added strength. Modal rayon fabric has a soft and luxurious feel, making it perfect for high-end clothing and household items.

Modal Fabric Properties

Modal fabric has the following properties:

Soft feel and luxurious touch
Highly breathable
More durable than cotton
Eco-friendly option
Moisture-wicking and water-absorbent
Lightweight and versatile
Drapes well

How is Modal Fabric Manufactured?

Modal fabric is a type of semi-synthetic fabric that is manufactured from cellulose fibers derived from beech tree pulp. The manufacturing process of modal fabric involves several steps:

Harvesting: Beech trees are harvested for their wood, primarily from sustainable forests.
Pulping: The harvested wood is chipped and processed to extract cellulose, which is then dissolved in a solvent to create a thick, viscous solution called “dope.”
Spinning: The cellulose dope is forced through spinnerets, which are small openings that resemble showerheads, to form continuous filaments. These filaments are then stretched to align the molecules and increase their strength.
Washing: The spun filaments are thoroughly washed to remove any residual chemicals or impurities.
Drying: The washed fibers are dried to remove excess moisture and obtain a suitable moisture content.
Finishing: The dried fibers can undergo various finishing processes, such as bleaching, dyeing, and printing, to achieve the desired color and appearance.
Weaving or Knitting: The modal fibers are woven or knitted to create the fabric.

It’s worth noting that the manufacturing process of modal fabric utilizes a solvent called sodium hydroxide, also known as caustic soda. While this chemical is used in the production process, it is typically recovered and recycled, minimizing its environmental impact.

Moreover, modal fabric is considered a more eco-friendly alternative to some other synthetic fabrics due to its biodegradability and the renewable source of its raw material.

Modal Fabric Production and Sustainability

Today, modal is produced by Lenzing AG, which uses sustainable manufacturing processes and practices. They produce Lenzing Modal, China Modal, and Formatex, and the lighter versions of the fabric – MicroModal and Lenzing Modal by Air, two types of modal fabric that use even less water.

The production of modal fabric is a semi-synthetic process that involves the use of chemicals. However, modal is still considered more eco-friendly than cotton due to the lower water usage in the production process.

Modal vs Other Fabrics

Modal vs Cotton

Modal fabric is more durable, flexible, and breathable than cotton. It is also softer to the touch and has a more luxurious feel. However, cotton is generally less expensive than makes of modal fabric.

Modal vs Viscose

Modal and viscose rayon are both types of rayon, but modal is more durable, flexible, and softer to the touch than viscose rayon.

Modal vs Lyocell

Modal rayon and lyocell are both types and forms of rayon, but lyocell is produced through a closed-loop production process that is more eco-friendly than the modal type of production process.

Modal Fabric Blends

Modal is often blended with other fibers like cotton, spandex, and polyester for added strength and flexibility. Modal fibers and blends are commonly used in athletic wear and sportswear due to their moisture-wicking properties. Modal fibers and blends are also used in bed sheets, pajamas, undergarments, underwear fabric, and clothing.

Modal-Cotton: A blend of modal and cotton is a popular choice for clothing, as it combines the softness of modal with the breathability of the cotton.
Modal-Spandex: A blend of modal and spandex is commonly used for athletic wear and sportswear, as it offers flexibility and breathability.
Modal-Bamboo: A blend of modal and bamboo is an eco-friendly option, as both fabrics are plant-based. This blend offers softness and breathability, making it a great choice for clothing and household items.

Modal Fabric Care Guide

Modal fabric is easy to care for and requires little maintenance. Modal fabric is known for its softness and durability, but it does require some special care to maintain its quality and appearance. Here are some tips on how to care for modal fabric:

Read the care label: Before washing your modal garment, always check the care label to see if there are any specific instructions. Some modal garments may require hand washing or dry cleaning, while others can be machine washed.
Wash in cold water: When washing modal fabric, ideally you’ll want to use cold water. Hot water can damage the fibers and cause shrinking or stretching. Use a gentle cycle and avoid washing with heavy or abrasive fabrics that could cause pilling or snagging.
Use a mild detergent: Choose a mild detergent that is specifically designed for delicate fabrics. Avoid using fabric softeners or bleach, as these can damage the fibers and cause discoloration.
Dry flat or hang to dry: After washing, avoid using a dryer, as the heat can damage the fibers and cause shrinkage. Instead, lay the garment flat on a towel or hang it to dry in a well-ventilated area.
Iron or steam as needed: Modal fabric is prone to wrinkling, so you may need to iron or steam your garment to remove any wrinkles. Use a low heat setting and avoid pressing too hard, as this can damage the fibers.
Store properly: When storing your modal garment, avoid hanging it on a hanger for long periods of time, as this can cause stretching. Instead, fold it neatly and store it in a drawer or on a shelf.

Modal-Sustainable: Is Modal an Eco-Friendly Fabric?

Modal is considered a more eco-friendly alternative and sustainable textile option rather than other plant-based textiles like cotton and viscose. The production process uses less water than cotton, and beech trees require fewer resources to grow than other types of trees.

Additionally, Lenzing AG, the company that produces MicroModal and Modal Air, uses a closed-loop production process that recycles 99% of the chemicals used in the production process.

Modal Cost: How Much Does Modal Fabric Cost?

Modal is a type of semi-synthetic fabric considered a high-end fabric due to its luxurious feel and durability. The cost of modal fabric can vary depending on the brand and the type of the modal fabric sustainable used.

MicroModal and Modal Air are two high-quality types of semi-synthetic fabrics of modal that are known for their softness and durability, but they also come with a higher price tag.

What are the pros and cons of modal fabric?

Pros of Modal Fabric

Softness: Modal is known for its softness and smooth texture, which makes it comfortable to wear.
Breathability: Modal is highly breathable, which means it can help regulate body temperature and keep you cool in warm weather.
Durability: Modal is a strong and durable fabric that can withstand regular wear and washing.
Absorbency: Modal is more absorbent than cotton, which means it can absorb moisture and sweat more effectively.
Color Retention: Modal holds dye well, so colors tend to stay vibrant and true even after multiple washings.
Sustainable: Modal is made from renewable beech trees, making it a more sustainable option than some synthetic fabrics.
Biodegradable: Modal is biodegradable.
Not Wrinkly: Modal fabric needs minimal ironing or steaming to maintain a smooth appearance.

Cons of Modal Fabric

Shrinkage: 100% modal fabric is less likely to shrink in the wash, but modal blends might shrink when exposed to heat, so it’s important to follow the care instructions carefully.
Fading: While modal holds dye well, it may still fade over time, especially with frequent washing and exposure to sunlight.
Cost: Modal is typically more expensive than some other fabrics, such as cotton or polyester.

Popular Uses of Modal Fabric

Modal fabric has become increasingly popular in recent years due to its versatility and softness. It is commonly used in a range of products including bedding, towels, undergarments, socks, t-shirts, athletic wear, and pajamas.

Many well-known brands such as Land’s End and Banana Republic offer affordable modal clothing options, and there is also a good variety of modal clothing and household items available on Amazon.

Compared to similar products made from polyester or nylon, modal fabric may be slightly more expensive. For instance, a modal blend t-shirt could cost around $30, which is higher than the $10-$15 you might expect to pay for a polyester shirt. However, the price difference may vary depending on the brand and style of the product.

In some cases, the cost of modal fabric items may be only slightly higher than their cotton counterparts. For example, you may find a set of modal, bed sheets are priced only five dollars more than a set of cotton sheets.

Clothing

One of the most popular uses of modal fabric is in clothing. Due to its soft texture, modal fabric is commonly used to make clothing items such as shirts, dresses, skirts, pajamas, and underwear. It is also known for its breathability, which makes it a great choice for activewear.

Modal fabric is often blended with other fibers such as spandex to provide stretch and improved durability. Its ability to retain color well also makes it a popular choice for clothing items that require vibrant and long-lasting colors.

Bedding

Modal fabric is also commonly used to make bedding items such as sheets, pillowcases, and duvet covers. Its moisture-wicking properties make it a good choice for those who tend to sweat at night, helping to keep them dry and comfortable. Modal fabric is also soft and lightweight, making it a popular choice for those who prefer a cozy and comfortable sleeping experience.

Towels

Another popular use of modal fabric is in the production of towels and washcloths. Modal fabric is highly absorbent, making it a great material for towels. It is also quick-drying, which can help prevent mildew and odors. Towels made from modal fabric are also known for their softness, which can provide a more luxurious and comfortable drying experience.

Active Wear

Modal fabric’s softness, breathability, and moisture-wicking properties make it a great choice for activewear. Clothing items such as yoga pants and sports bras made from modal fabric provide comfort and breathability during exercise.

Modal fabric is also lightweight, making it a popular choice for those who prefer to wear lightweight clothing during physical activities.

Accessories

Modal fabric can also be used to make accessories such as scarves and shawls. Its lightweight and soft texture make it a comfortable option for all-day wear.

Modal fabric is also known for its ability to retain color, which makes it a popular choice for accessories that require vibrant and long-lasting colors.

Conclusion

Modal is a luxurious and versatile fabric that is made from beech tree wood pulp. It is known for its softness, breathability, and eco-friendliness. Modal is a great and sustainable alternative to cotton and viscose, as it is more durable and flexible. It is often blended with other fabrics like cotton and spandex to enhance its properties.

While modal is more expensive than other sustainable fashion fabrics used, its durability and eco-friendliness make it a worthwhile investment. When caring for modal clothes, it is best to wash them in cold water and avoid using bleach and fabric softener.

Modal Fabric FAQ’s

Is modal better than cotton?

Modal is indeed softer and more durable due to its finer knitting. Modal fabrics are strong and last longer than regular cotton clothes. Modal remains stable long after washing.

Is modal fabric good for kids?

Yes, modal fabric can be a good choice for kids. It is known for its softness, breathability, and moisture-wicking properties, making it comfortable to wear, especially for children with sensitive skin. Modal fabric lasts longer compared to cotton and has better resiliency than most other synthetics.

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