Manufacturing Process of Yoga Mats

Manufacturing Process of Yoga Mats

Yoga is an exercise that helps in muscle relaxation, allows your body to move in various directions, increase flexibility, improves breathing, and relax mind and body. Yoga is believed to be a mental, physical, and spiritual practice which was originated in ancient India. Yoga aims to control and still the mind and detach yourself from activities of mind and mundane sufferings. In ancient India, people did not use yoga mats to perform yoga. Instead, they place curtains on the floor and meditate.

As the people developed, they invented unique yoga mats to perform yoga. Yoga mats are made up of special materials, and they are different from general mats and curtains or carpets. They are designed to be non-slippery and prevent joints from the impacts of the floor. Generally, there are two types of yoga mats:

Single-layer or conventional yoga mat

Multilayer or body alignment yoga mat

We will discuss the production process of both yoga mats in this article. So if you are interested in yoga and want to know how yoga mats are produced but don’t have time to visit the factory to observe the manufacturing process, give this article a read.

Single Layer or Conventional Yoga Mat

The conventional yoga mat has a clear bubble point front and flat esthetic back. It is a simple, comfortable, soft, and low-cost product. Although new types of yoga mats have been around for a while, many people still use these simple traditional yoga mats to perform meditation.

Manufacturing Process

  1. Make compounding material

The first step is to select a suitable and good quality raw material according to the formula and mix it with the latex mixture.

  1. Adjusting machines

Now adjust the boiler to preheat the machine. Set and adjust the parameters of each district and install the related material and mesh cloth on the machine in place.

  1. Brushing

In this step, we will tighten the mesh cloth to the needle track; then, we will flatten it and brush it.

  1. High-Temperature Foaming

The previously brushed mesh cloth is drawn to the foaming moulding chamber at high temperature through the needle plate.

  1. Cooling

Once the foaming has been done, the product will be drawn out of the chamber to dissipate heat, then cooled and shaped.

  1. Cutting corners

Adjust the tool holder at some distance to the end of the machine and cut the product according to customers’ requirements.

  1. Slicing

The product is sliced to the desired thickness

  1. Embossing

In this step, the anti-slip stripes are made.

  1. Sizing

Sizing is a term designated to the process in which a product is cut to the required size according to the customer’s requirements.

  1. Graphic Printing

Laser marking or UV printing is used to print the pattern on yoga mats

  1. Logo Marking

Again, laser marking or screen printing is used to print the customer’s logo on yoga mats.

  1. Quality Inspection

Carefully inspect the quality of yoga mats. Mats that are up to 100% perfection will be shipped to customers only. Other defective ones will be discarded.

  1. Packing

Pack the products and store them in storage. Now the product is ready to be shipped.

Multilayer or Body Alignment Yoga Mats

Multilayer or body alignment yoga mats are advanced high technology yoga mats with anti-slip design, alignment lines and gorgeous patterns. Mainly, the multilayer yoga mat has a three-layered structure.

The first layer of the yoga mat is imprinted with parallel or perpendicular laser printed positive marks, crosses. These crosses tell the yoga practitioner the correct position of performing yoga. It will also prevent unnecessary injuries, and it will improve the immune system.

The middle layer is made up of special cotton fibres. It is designed to absorb and disperse water quickly and protect you and your mats from the accumulation of bacteria.

The third layer or ground layer is made up of natural rubber. It will significantly boost the grip performance of the mat. This layer greatly reduces slipping and bring comfort to the person who is performing the yoga exercise.

Manufacturing Process

  1. Produce a compounding material

Select an appropriate raw material according to the formula and mix it with latex mixture to make the compounding material.

  1. Adjusting Machines

Set the boiler to preheat the machine. Set and adjust the parameters of each district. Install the related material and mesh cloth on the machine in the right place.

  1. Brushing

The process of brushing includes tightening of mesh cloth to the needle track and flattening and brushing it afterwards.

  1. High-Temperature Foaming

The brushed mesh cloth, which has undergone a brushing process, is taken to the foaming moulding chamber of high temperature through the needle plate.

  1. Cooling

The product is drawn out from a high-temperature foaming chamber to dissipate heat, cool and shape the product.

  1. Cutting corners

The tool holder is adjusted at a distance at the end of the machine, and the product is cut according to the customer’s demands.

  1. Slicing

Slicing is the continuation of the previous process. Here the product is continuously cut until the desired thickness is achieved.

  1. Hot Pressing of Multiple Layers

The half-finished multi-layered product is stacked neatly in order and then laminated into the whole by a hot press.

  1. Embossing

The anti-slip stripes are made in this process

  1. Sizing

Cut the yoga mats to the required size of customers.

  1. Graphic Printing

Laser marking or UV printing is used to print the pattern on the yoga mats.

  1. Logo Printing

The logo of the customer is printed onto the yoga mats through laser marking or screen printing.

  1. Quality Inspection

The quality of each yoga mat is strictly observed, and any defective product, even the slight defect, will not be delivered to the customer.

  1. Packing

Pack the excellent quality products and send them to the storage room from where they will be shipped to the customers.

Final Verdict

Yoga exercise initially originated in ancient India, but now people worldwide are performing yoga. Use high technology yoga mats to save yourself from joint injuries. This guide provides the complete details of how different types of yoga mats are manufactured. Read the article and choose the mat which you think would be the best for you.

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