Manufacturing Process

Every incoming batch of yarn, fiber, chemical, and additive is inspected against specification. Yarn samples are tested for tensile strength, count consistency, and twist uniformity before release to production. Non-conforming materials are quarantined and returned.

Approved yarns are loaded onto rapier or air-jet looms and woven with precision control. Computer-optimised settings ensure consistent fabric density, GSM, and width — typically within ±3% tolerance. Greige fabric is inspected, rolled, and labelled for transfer to the dyeing workshop.

Greige fabric is scoured, heat-set, and dyed in jet dyeing machines with controlled temperature ramps and chemical dosing. Finishing processes include sanforizing, chemical application (DWR, antibacterial, FR), and mechanical finishing for hand feel and drape.

Finished fabric passes through precision coating lines for PU, acrylic, or silicone application. For waterproof breathable fabrics, hot-melt lamination bonds a membrane to the face fabric. Coating thickness is monitored continuously with IR sensors.

Custom branded fabrics are printed using high-resolution digital inkjet printers with eco-friendly water-based inks. Prints are cured and fixed for wash fastness and UV resistance. Suitable for apparel, flags, and specialty textiles.

Every fabric roll passes through automated inspection frames. Defects are flagged, measured, and graded per ASTM D5430. Samples are cut for lab testing (tensile, hydrostatic head, colorfastness, shrinkage). Each roll receives a unique batch number.

Representative samples from every batch undergo mandatory performance testing: tensile strength (ASTM D5034), tear strength (ASTM D2261), hydrostatic head (AATCC 127), UPF rating (AS/NZS 4399), colorfastness (AATCC 61), and shrinkage (AATCC 135).

Approved rolls are wrapped in PE film, labelled with batch details and spec sheet, and packed in woven bags or cartons. We coordinate with freight forwarders for FCL and LCL container shipments worldwide.