SAMPLING
Product samples are developed on our handloom to accurately replicate the required weave, construction and design. Samples are submitted to the buyer for evaluation and approval. Bulk production commences only after buyer approval.
YARN PROCUREMENT
We use use 100% Cotton Yarn, Organic Cotton Yarn, 100% Polyester Yarn, Poly-Cotton Yarn, and Recycled Yarn in our manufacturing process. These yarns are sourced primarily from our sister concern spinning mills and also from a network of approved suppliers.Every incoming yarn lot undergoes a comprehensive quality inspection for count, count variation, strength, twist, contamination, fibre composition, and shade consistency to ensure it meets our quality standards.Once the yarn successfully passes our quality inspection and receives internal approval, it proceeds to the next stage of production. Only approved yarn lots are released for manufacturing, ensuring consistent quality throughout the production process.
DYEING (YARN / FABRIC)
Yarn or fabric is dyed based on product requirements using AZO-free, eco-friendly dyes under controlled processing conditions. Shade consistency and dimensional stability are carefully monitored throughout the process. Colour accuracy is verified using a Colour Matching Cabinet with international standard light sources (D65, TL84, CWF, F/A, UV and U30) to ensure consistent shade matching and detect metamerism.
WEAVING
Fabric is woven using advanced Somet, Rapier and Vamatex shuttleless looms with widths from 44" to 108" (up to 118" on request). We manufacture Plain, Twill, Satin, Oxford, Canvas, Jacquard, Dobby, Seersucker, Waffle, Herringbone, Leno, Muslin and Double Cloth constructions. Reed, pick, GSM, width and shrinkage are monitored throughout the weaving process.
PRINTING
We specialize in Pigment, Reactive, Discharge, Khadi, Table Print and All-Over Printing. Every printed fabric is produced under controlled conditions and inspected for print quality, shade, design accuracy and defects before moving to the next manufacturing stage.
EMBROIDERY
We use Barudan ,Tajima and SWF machines 6nos each with 20 head /12 colour for embroidery orders from customers.Embroidery stitch quality and design is checked by our Quality controllers before the fabric is moved to the next process.
FABRIC INSPECTION & CUTTING
Dedicated quality inspectors monitor every stage of production to identify and correct defects early. Fabric inspected for GSM, width, construction, shrinkage, shade, and design. Optimized marker planning for minimum fabric wastage. Precision cutting as per approved specifications.
STITCHING
Our products are stitched using modern sewing machines ( JUKI, JACK, and SIRUBA) . Experienced operators work across our stitching units . Every production line is supervised by Line Supervisors and QC.In-line quality checks are made to ensure consistent workmanship and product quality. More than 70% of our workforce consists of skilled women employees,contributing significantly to the workmanship, quality, precision and effeciency of our stitching process.
FIBER OPENING & FILLING
We work with a wide range of premium-quality fibers including Conjugated Fiber, Hollow Siliconized Fiber, Siliconized Fiber, Non Siliconized Fiber, Slick Fiber (Fire Retardant), 100% Cotton, Waste Cotton and Recycled PET Bottle Fiber . We use premium-quality fibers procured from approved local suppliers as well as imported materials , based on buyer requirements.Fibers are processed through our fiber opening machine to achieve uniform loft, softness, and consistency before filling. Cushions, pillows, bolsters, and chair cushions are filled using controlled processes to achieve the specified weight and firmness. Every filled product undergoes a 100% filling inspection to verify the correct fiber type, filling weight, and consistency as per the buyer's specifications.
VACUUM PACKING & COMPRESSION
Compresses finished cushions and pillows by removing excess air, reducing storage space and shipping volume.Shapes and compresses finished cushions and pillows to ensure a uniform appearance before packing.
QUALITY CHECKING
Every product undergoes systematic in-line and final quality inspections to ensure it meets buyer specifications. Measurements, stitching quality, workmanship, appearance, and finishing are carefully checked before packing. More than 95% of our workforce consists of skilled women employees, contributing significantly to the quality, precision and effeciency of our quality checking.
PACKING
After the final quality inspection, every product undergoes a pre-packing verification to ensure complete accuracy before packing. Product labels, hang tags, barcode stickers, care labels, and other packaging components are carefully verified against the approved buyer specifications to ensure they are correctly matched with each product. Products are then folded, ironed (where required), individually packed in polybags or master polybags as per buyer requirements, and packed into export cartons. A final carton verification is carried out before sealing, after which the goods are palletized (if required) and loaded into containers for shipment.
STORAGE & PRE-SHIPMENT INSPECTION
After packing, finished goods are securely stored in our warehouse under organized storage conditions until shipment. Prior to container loading, a comprehensive pre-shipment verification is conducted to confirm carton quality, carton markings, serial numbers, barcode numbers and shipment quantities against the approved packing list. This final verification ensures complete shipment accuracy before the goods are loaded into the container.
CONTAINER LOADING
Containers loaded as per the approved packing plan. Final checks confirm the correct quantity, styles, and cartons are loaded before sealing and dispatch.
SHIPPING & EXPORT
Sealed containers are transported to the buyer's nominated port, including Tuticorin, Nhava Sheva (Mumbai), Chennai, Cochin , or other required ports. Export customs clearance and statutory documentation are completed before container stuffing and vessel loading. Containers are securely sealed and loaded onto the designated vessel for shipment to the customer's destination. We currently offer shipments under Ex-Factory, FOB and CIF incoterms only.
