OUR  MANUFACTURING  PROCESS

 

                                

 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 PROCUREMENT                                   

                       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, Yarn-Dyed Stripes / Checks, 
                     Patterns, Jacquards, Dobbies, and customized developments. We can 
                     weave around 1,00,000 flawless metres per month. Fabric Reed / Pick, GSM,
                     width, and Shrinkage are monitored throughout the weaving stage.
                      
 
 
 

 

              

                                  PRINTING

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

 

 

 

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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.

 

 

                                                                                                              

                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.

 

 

                 

                          VACCUM 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.