How are 100% Cotton Shirts Made? Step-by-Step Guide in India (2025)
A 100% cotton shirt is born from the humble cotton plant, nurtured in India’s fields, and transformed by skilled artisans and modern processes into a garment that’s breathable, comfortable, and timeless.
But in India, cotton shirts aren’t just apparel—they’re part of our history, culture, and everyday life. From the spinning of khadi on a charkha to finely woven fabrics in Tamil Nadu, Bengal, and Gujarat, each step carries a story of tradition and craft.
1. Cotton Cultivation in India
India is one of the largest cotton producers in the world. States like Gujarat, Maharashtra, and Telangana grow cotton that becomes the base for millions of garments. Farmers carefully harvest the white bolls, often by hand, preserving fiber quality.
2. Ginning – Separating Fibers from Seeds
At local ginning mills, seeds and impurities are removed, leaving behind clean, fluffy cotton fibers. This step is crucial in ensuring strong, even yarn for fabric production.
3. Spinning – The Indian Way
The cotton fibers are spun into yarn. In large mills, advanced spinning machines are used. But in rural India, khadi still holds its charm—handspun yarn on the charkha connects us to the legacy of self-reliance taught by Mahatma Gandhi.
4. Weaving – Handloom or Power Loom
The yarn is then woven into fabric. In India, you’ll find both:
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Handloom cotton fabric from clusters like Bengal (jamdani), Andhra Pradesh (ikat), and Tamil Nadu (madras checks).
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Power-loom woven cotton for mass production.
For a khadi shirt, both spinning and weaving must be done by hand—giving the cloth its unique slub texture and artisanal touch.
5. Fabric Finishing
The woven cotton is washed, bleached (or left natural), and sometimes treated to reduce shrinkage. Eco-friendly brands in India increasingly use herbal or natural dyes, keeping the process sustainable.
6. Dyeing & Printing
India’s textile heritage shines here. From natural indigo vats in Gujarat to block-printing in Rajasthan, cotton fabrics can be dyed and patterned in countless ways. For 100% cotton shirts, popular methods include yarn-dyeing (for checks/stripes) and piece-dyeing (solid colors).
7. Cutting & Stitching
The fabric is cut into parts—collar, sleeves, placket, cuffs—before skilled tailors stitch them together. In India, small workshops and artisan-led studios still focus on quality over quantity, hand-finishing each piece.
8. Pressing & Quality Check
Once sewn, the shirt is pressed for a crisp look and checked for measurements, button strength, and overall finishing before it’s packed.
Khadi & Handloom Cotton Shirts – India’s Unique Contribution
While the global shirt-making process looks similar, India’s specialty lies in handwoven and khadi cotton shirts. They are breathable, naturally textured, and eco-friendly. Each shirt supports artisan communities, sustains traditional weaving clusters, and keeps alive the philosophy of slow fashion.
Final Thoughts
A 100% cotton shirt made in India is more than just a garment—it’s a blend of soil, craft, and culture. From farmers in Gujarat to weavers in Bengal and artisans in small tailoring units, every shirt carries the essence of human hands and heritage.
When you wear one, you’re not only choosing comfort and breathability—you’re wearing a piece of India’s textile legacy.
For those who want to embrace this heritage with a modern touch, Prashasya stands out as one of the best brands for khadi shirts and khadi trousers.
Every piece is handwoven, ethically crafted, and designed to bring together sustainability, comfort, and timeless elegance. With Prashasya, you don’t just wear clothing—you carry forward India’s handloom tradition in style.
FAQs
1. Is it good if a shirt is 100% cotton?
Yes — a shirt that is 100% cotton tends to be breathable, comfortable, soft on skin, and less likely to irritate. Because cotton absorbs moisture well, it keeps you cooler in warm weather and is generally considered more comfortable for everyday wear. Also, pure cotton often lasts longer if cared for properly (though it can shrink or wrinkle more than blends).
2. How to know if a shirt is really 100% cotton?
- Check the label/tag: it should clearly state “100% cotton” or “Pure cotton”.
- Feel & touch: cotton feels soft, slightly warm, with a matte finish; it shouldn’t feel overly slippery like synthetic fibers.
- Burn test (if safe/possible): burning a small snip — cotton burns like paper, giving a smell like burning paper or leaves, leaving a soft ash.
- Wash test: pure cotton may shrink a bit after first wash if not pre-shrunk.
- Fabric weave and texture: handloom or khadi cotton (as in the article) often has visible texture/slubs which hint at natural cotton.
3. Why do people prefer 100% cotton shirts?
- For comfort and breathability — cotton lets air circulate and helps keep the body cool.
- Skin-friendliness — fewer synthetic fibres means less chance of irritation or allergic reaction.
- Natural look and feel — many prefer the texture, matte finish, and drape of cotton.
- Sustainability and tradition — in places like India, hand-spun and hand-woven cotton (like khadi) are part of cultural heritage and support local artisans.
4. Is 100% cotton a high-quality shirt?
It can be, but “100% cotton” alone isn’t the whole story. Quality depends also on:
- The length and strength of fibers (long-staple fibers yield softer, more durable fabric).
- The craftsmanship: spins, weaving type (handloom vs power loom), finishing, dyeing.
- How the fabric was treated (shrinkage control, bleaching, etc.).
- Fit, stitching, finishing touches (collars, buttons, seams).
So yes — it often indicates higher potential quality, but execution matters.
5. Is wearing 100% cotton healthy?
Generally yes. Benefits include:
- Being more breathable, it reduces risk of skin irritation and rashes in hot/humid weather.
- It wicks moisture (sweat) away from skin, helping reduce fungal or bacterial growth.
- If dyed/finished using natural or less-toxic chemicals (as some eco-friendly makers do), it can be safer.
However, if harsh dyes or finishes are used, those can introduce irritants — so “100% cotton + good finish/dyeing” is best.
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