Manufacturing & Processing
1. Raw Fiber Stage
Process:
Receive and inspect raw fiber (cotton, polyester, etc.)
Quality Control:
Check fiber length, strength, micronaire (fineness)
Test moisture content and impurity level
Approve only certified and standard-grade bales
2. Ginning (for natural fibers like cotton)
Process:
Separate lint (fiber) from seeds and clean the fiber.
Quality Control:
Monitor trash content and fiber uniformity
Ensure no contamination (plastic, leaf, or metal)
3. Spinning Process
Process Steps:
Opening & Cleaning – open fiber bales and remove dirt
Carding – align fibers
Drawing – combine slivers for uniformity
Roving – prepare for spinning
Spinning – twist into yarn
Winding – yarn wound on cones
Quality Control:
Test evenness (U%), count, tensile strength, elongation
Online yarn clearer system to cut thick or thin places automatically
Random lab testing of yarn samples
4. Weaving / Knitting
Process:
Convert yarn into fabric
Weaving: Interlacing warp and weft on loom
Knitting: Interlooping yarns with needles
Quality Control:
Before weaving: Check yarn tension, warp sizing, and beam setting
During weaving: Continuous loom monitoring
After weaving: 100% grey fabric inspection under 4-point system
Check for broken ends, miss picks, holes, oil stains, color variation
5. Grey Fabric Storage
Process:
Roll and store inspected greige fabric properly
Quality Control:
Maintain humidity & temperature
Label with lot number, loom number, and inspection result
6. Pretreatment / Preparation
Process Steps:
Singeing – remove surface hair
Desizing – remove size (starch or PVA)
Scouring – remove oils, waxes, impurities
Bleaching – whiten the fabric
Quality Control:
Check absorbency test, pH value, whiteness index, and weight loss
Inspect fabric for any damage or uneven processing
7. Dyeing / Printing
Process:
Apply color or pattern to the fabric
Quality Control:
Check shade matching (Lab D65 light)
Lab dip approval before bulk dyeing
Control dye liquor pH, temperature, and time
Test color fastness to washing, rubbing, and light
8. Finishing
Process:
Apply chemical or mechanical finishes (soft finish, shrink control, etc.)
Use stenter, compactor, or calendar machine
Quality Control:
Test fabric width, GSM, shrinkage, hand feel, tear strength
Check for chemical residue and uniform finish
Conduct fabric performance tests (e.g., wrinkle recovery, smoothness)
9. Final Inspection
Process:
100% inspection under controlled lighting as per 4-point or 10-point system
Quality Control:
Check for color uniformity, stains, weaving faults, holes, oil marks
Use shade continuity check for large lots
10. Packing & Dispatch
Process:
Fold or roll fabric, label, and pack according to buyer’s specification
Quality Control:
Random recheck before dispatch
Verify measurement, labeling accuracy, carton strength
Final AQL inspection before shipment