PRESENTATION

Fabrication Process Flow

Global Exports

Marketing
Order & Follow Up

Merchandis Knitting Dyeing Finishing

Resource &
MIS Q/A
Coordinate Fabric
Correspond Dyeing & Drying Compaction TQM
Manufacturing\

Yarn
Resource & Procure

GGT
Feasiblity Management

Fabrication
Processing Fabric
MARKETING

• Order Generation
• Correspond with customer
• Necessary follow ups Internal & External
MERCHANDISING

• Correspond with Customer

• Initiate the Program Requirements
• Necessary Procurements
• Provides Tech Pack & CSP
• Provides Size, GSM, Shade & Shrinkage Criteria
MANAGEMENT INFORMATION SYSTEM (MIS)

• Assist Merchandising
• Data Input
• Inform & Collaborates with related departments like
• GGT, Yarn, Fabrication
YARN
RING YARN IS PREFERRED OVER CONE YARN

• Yarn Thickness Increases in descending order in Numbers

• Procure Yarn on priority bases for exports orders
• Total Bags required x 1 Bag KG i.e. 45.36 = Total Required KGs
• Total Required KGs / Total Pcs Required = Per Pc Weight
GERBER GARMENTS TECHNOLOGY (GGT)

• Draft efficient Patterns

• Draft low wastage cutting markers minimize fabric losses
• They provide the cutting range / layers plan according to Order size Ratio
 FABRICATION

• Procure fabric from Knitting & Following Up

• Fabric Stocking & Issuing
• Allocating Machines for knitting based on Required Gauge / Dia / GSM
• Grey Fabric Inspection: Needle Line, Oil Spot, Dead Cotton,
Needle Hole, Strips, Cuts, Holes, Shinker Line, Rafu
KNITTING

• Mostly In-house then Commercial respectively

• Usually Circular Knitting is being followed
• Single Yarn Knitting: (1 Count) Single Jersey
• Double Yarn Knitting: (Same Count 2 Yarns) Rib 1x1, 2x1, Plain & Interlock
• 2 End Knitting: (2 Same / Different Count Yarn) 2 End Fleece / Terry
• 3 End Knitting: (2 Same & 1 Diff or all 3 / Different Count Yarn) 3 End Fleece / Terry
 DYEING & WASHING
MACHINES FROM 25KG TO 2,800 KG

• Initially Lab builds Sample for shade approval

• Generating recipes, allocating machines based on weight
• Our 8 Sample Machines are:
Machine No Capacity (KG) Specification
Sample Jet – 2 50 Both Portion Dyeing
Sample – 1 100 Single Portion Dyeing
Sample – 2 20 Single Portion Dyeing
Sample – 4 30 Single Portion Dyeing
Sample Jet N – 1 25 Both Portion Dyeing
Sample Jet N – 2 50 Both Portion Dyeing
Sample Jet – 5 200 Both Portion Dyeing
Sample Jet – 6 100 Both Portion Dyeing
DYEING & WASHING

• Our Bulk Production Machines are:

Machine No Capacity (KG) Specification
2 600 White / Haider Grey
3 2800 Both Portion
Dyeing
4 2500 Both Portion
Dyeing
6 150 Single Portion
Dyeing
7 400 Single Portion
Dyeing
8 400 Both Portion
Dyeing
9 600 Single Portion
Dyeing
10 650 Both Portion
DRYING PROCESS

• On Urgency:
Blowning & Conveyer Dryer
• For Good GSM Hydro Dryer & Hanger

• Slitting Process to Open Tubes fabric if required

FABRIC BRUSHING
ON REQUIRED BASES

RAISING
• Process on back of fabric to make it
soft & thik
• Fabric Before Raise is French Terry
• Fabric After Raise is Fleece
• Once raising done it wont revert back
to Terry
PEACHING
• Process on front to make fabric soft &
silky
• This process may get done on other
fabrics than Fleece as well
FINISHING PROCESS

COMPACTION FOR OPEN FORM COMPACTION FOR TUBE FORM

• Stantering for softener, adjust weft
while maintaining GSM, Shrinkage
control, Steaming
• If GSM need to adjust further then we
Process it with Lafer and compact it
accordingly
• Using Ferraro for softner, adjust weft while
mantaining GSM, Shrinkage control, Steaming
• If GSM need to adjust further then we steam it
with Tube Tex and compact it accordingly
• Heatset Process to adjust Lycra
• Soft Set for further Plating
QUALITY ASSURANCE
GSM & SHADE

• Collects swatches for GSM & Shade

• Make GSM Card & Shade Card for Aproval
• GSM Formulation:
(GSM of All Rolls) / No. of Rolls
• Shade will be matched with approved shade Card
QUALITY ASSURANCE
SHRINKAGE PROCESS

• Marking Length, width

• Washing Drying & evaluate markings by:
• Length & Width
Size Before Wash - After Wash = Shrinkage
Shrinkage / Before Wash Size %
FINISHED & READY FOR STICH
TYPES OF FABRICS

• Single Jersey • Platted Pique

• French Terry 2end & 3end • Ottoman / Quilted / Jacquard Fabric
• Fleece 2end & 3end • Double Loop Terry
• Ribs Plain & 1x1 , 2x1 with Lycra • Tight Knit Straight Fleece
• Pique • Tight Knit Cross Fleece
• Sponge Pique
• Interlock
TYPES OF COUNT
YARN THICKNESS

Yarn Thickness increases in descending order

• Conventional Yarn
• Recycled Yarn ( Re- Generated Yarn Called RG Yarn )
• Mélange Yarn
• Naps Yarn
• Twisted Yarn
• Space dye Yarn
• Injected Yarn
YARN CONTENT
YARN COMPOSITION

• Cotton: 100% Cotton

• PC 52% Poly / 48% Cotton and 65% Poly / 35% Cotton
• Heather Grey 90% Cotton 10/Poly and Other Content as per Demand
• CVC 60/40,
• Lycra 40 D, 30 D