Experimental and theoretical investigation of loop strength in terry fabrics: A modified single-loop extraction method and weave parameter optimization

The durability of terry fabrics largely depends on the fixation strength of pile loops. However, existing standard test methods such as BS EN 15598 and GOST 23351-78 measure the combined resistance of multiple loops and cannot isolate the structural contribution of individual loop anchoring. This study investigates loop fixation strength in terry fabrics through an integrated experimental and theoretical approach. A modified single-loop extraction method was developed in which adjacent loops were removed prior to testing to ensure that the measured force corresponded to a single pile loop. The method demonstrated high repeatability with coefficients of variation below 4.5%. A mechanistic model describing loop extraction resistance was formulated based on three physical components: pile–weft compression force, reed dent confinement force, and frictional wrap resistance. The model predicted experimental results with a mean absolute percentage error of 9.6% across five fabric structures; its predictive applicability is therefore preliminary and limited to the investigated parameter range (weft yarn linear density Nm 15–27, loop height 5–11 mm). Five 100% cotton terry fabrics, including four industrial samples and one proposed weave structure, were experimentally evaluated. The modified four-pick weave doubled the number of pile–weft contact points and achieved a loop extraction strength of 51.0 cN, representing a 16% improvement over the strongest industrial sample. The results demonstrate that weave architecture, inter-yarn spacing, and yarn–reed coordination are key structural parameters governing loop stability and can be optimized to improve the durability of terry textile products.