I'm curious to know how everyone separates towels so they can be hemmed. Previously I would take it to the serger, set the density to about where I would and serge them, wash them, and then hem them on my sewing machine. Recently my parents let me know 2 towels I made (of the many they now have) are starting to fray at the hems. It looks like the serged part inside the hem failed but the straight stitch on the hem has held. Has anyone else had this happen with serged towels? How do you all tackle doing the stitching to separate your towels? Do you prefer zig zag? Or do you use a straight stitch or something else?

If you close the edges of your hem, the serged edge is fully enclosed. So, stitch the edge, turn and stitch the hem, then stitch the other edge. Bit fiddly, but secure.

The serged edge was enclosed in the hem but a section of the hem started to unravel from the inside, but the sewing machine stitches to close the hem were intact. I'm just not sure how it happened, I have a feeling the 10/2 mercerized cotton might be part of the problem? Or maybe I need to adjust the stitch length on the serger?

Maybe make the hem edge larger—I use 1/2”+ when weaving which allows for some to get eaten during seeing, then the hem that shows is your preferred width. This might make the threads stay put better. If you are concerned about bulk, use finer thread for the first hem section. Sewing thread or 16/2 work well.

As you suggest, a tighter stitch on the serger might be the answer.

I usually weave 1.5” for my hems, so maybe I’ll do a little longer and do a tighter serger. I’m experimenting with just a denser straight stitch too on my normal sewing machine as I don’t have a machine that does zig.

I weave 2" between towels for hems. 1" either plain weve of just continue the pattern, trow 2 picks in the same shed for a clear cutting line and another inch for the next hem. Wet finish, dry, iron and at the same time cut the individual towels and fold/iron the hem. Simple straight stitch on the machine while adding a loop for hanging and finished!