PRODUCTION PROCESS-KNITS

By Sunil Talekar, Student handout-SOFT -Pune

PRODUCT DEVELOPMENT
The Product Development section is a window for new buyers in term of pricing, sampling and information collection. The department provides assistance on a micro level, something that is essential to the growth of any account.

PRE PRODUCTION PROCESS

Effective management of Pre Production approvals process is critical to delivering a great quality product on time.

Pre production team works with well articulated and well thought out timings and action calendars ensuring that each product is ready for production in the true sense before it gets handed over to production department for manufacturing.

PRODUCTION PROCESS KNITTING

Fabric is produced on Circular knitting machines, as per required structure. Principal yarns are cotton and cotton blends including Lycra. Fabric range is single jersey, pique, interlock 2/3 thread fleece, thermals, waffles, jaquards and feeder / auto stripe jersey / interlocks.

Trims are made on flat knit machines. Sometime a database of all fabric development and production to ensure reproducibility and give a wide choice to the buyers.

CIRCULAR KNITTING MACHINE

FLAT BED KNITTING MACHINE

FLAT BED KNITTING MACHINE

PRODUCTION PROCESS DYEING

Fabric is dyed using the latest soft flow technology. Reactive dyes are used to meet the international standards of dyed fabric performance. Polyester dyeing is also available along with reliable resource base for yarn dyeing.

PRODUCTION PROCESS FABRIC FINISHING

Complete finishing range for all types of knitted fabrics, done on squeezer horizontal dryer, compactor for proper fabric handle and ensure fabric stability.

PATTERN & CUTTING

CAD system is used to make precise patterns and grading as well as planning a lay and markers for efficient and accurate cutting.

In line inspection of cut goods is carried out before it is transferred to the stitching department.

PRODUCTION PROCESS- PRINTING

Printing is being done manually & automatic machines. Printing options are Water based screen Plastisol High Dynasty Flocking Foil Discharge print Heat transfer.

FLOCKING- PRINTING
The flock printing is a latest technology to make an artificial velvet surface with Electrostatic Flocking Equipment's. This can be done on any kind of fabric & garments on any part of the garments giving very soft hand feel. The flock printing is done by flock sheets by transfering flock paper on fabric.

HIGH DENSITY- PRINTING

High density screen printing at first glance seems to be some sort of high-quality puff print.

FOIL- PRINTING
Foil Sparkles Shimmers are used for applications like giving flashing effect on cloth, enhancing color shade after printing, giving a lamination effect, giving transparent effects Giving very soft hand feel & color fasteners towards world class standards & world class ECO System.

PUFF- PRINTING

WATER BASE- PRINTING

PRODUCTION PROCESS-EMBROIDERY Appliqus are being attached by hand with gum and then embroidery is done by using most advanced Tajima & Barrudan machines.

PRODUCTION PROCESS-STITCHING
Stitching machines to assemble polo shirts, pieced garments, rugby, henleys and other styles. Time-motion studies, using industrial engineering techniques are used to plan production lines for every style that goes into production.

Unique trolley system to transport parts from one stitching station to the other has reduced the through-put time from 3 days to 6 hrs.

PRODUCTION PROCESS-FINISHING & PACKING.

In finishing all stitched garments are being checked for quality and appearance and then finaly after folding and poly packing goes to cartons.

THANK YOU