We start our manufacturing process by procurement of yarn from our supplier. In order to avoid merging of different qualities, yarn is stored as per the lot number & quality.
Basically knitting process is a repetitive action to create terry loops. We use Pai lung, Fukuhara, Orizio, Belasus, Mayer & Cie, & Monarch Knitting Machines. GSM & diameter of the greige fabric is set as per the customer’s requirement. Greige fabric is in tubular form & is passed on to the next process after inspection.
Dyeing is done using HTHP jet dyeing
Sampling Jet: 50 kgs
Bulk jet: 180 kgs
Production lots are in batches of 165 kgs
Minimum sampling quantity: 40 kgs
Colors are Azo Free & confirm to Oeko-tex 100 standard.
FINISHING
Raising (or Napping) is done to develop fur on the fabric surface. In order to ensure uniform pile height the raised fabric is further raised by the combing machine & leveled by the shearing machine. Tumbling is done to render anti-pill effect to the fleece fabric. Heat setting is done to stabilize the dimensions of the fabric and to achieve the GSM as per the customer’s requirement. This process is done using a gas heated stenter.
QUALITY CONTROL
Inspection is done at the following stages
After Greige production (GSM, holes, slubs, knitting defects, width)
After Dyeing (Color fastness @ 60o C, D-65 Color Matching)
After Stenter (Final GSM, Width, Shade Variation, Stains, etc)
Additional test reports like pilling, rubbing fastness, dimensional tolerance can be requested from SGS lab. Testing fee will be charged to the customer’s account.
