FACTORY   WORKFLOW

 

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 of the sample, ensuring the final product matches the approved quality and specifications.

 

 

 

 

 

 

YARN 

 

We 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 woven using advanced Somet, Rapier, and Vamatex shuttleless looms with widths from 44" to 108" (up to 118" on request).
  • We manufacture a wide range of Plain, Twill, Satin, Oxford, Canvas, Jacquard, Dobby, Seersucker, Waffle, Herringbone, Leno, Muslin, Double Cloth, and other specialty weaves.
  • Designs include Solids, Stripes, Checks, Gingham Checks, Yarn-Dyed Patterns, Jacquards, Dobbies, and customized developments.
  • We can produce around 1, 00,000 flawless metres per month.
  • Fabric Reed / Pick construction , GSM , width, and Shrinkage are monitored throughout the weaving process.
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 PRINTING

We specialize in Pigment, Reactive, Discharge, Khadi, Table print, and All-Over Printing.Printing is carried out under controlled processes to ensure consistent quality. Every printed fabric is inspected for print quality, shade, desgin and defects before moving to the next stage.

 

 

 


 

EMBROIDERY

 

we use Barudan and Tajima machines 4nos 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. 

 

 

 

 

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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.

 

 

 

       

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 vessel loading.                      Containers are securely sealed and loaded onto the designated vessel for shipment to the customer's destination.