Rolls of freshly dyed knitted fabric in the finishing department

Manufacturing

From concept to closet, without leaving the group.

Seven stages, all of them ours. Here is what happens between the yarn arriving and the carton being sealed.

~30: Knitting machines; Single jersey, rib, interlock, terry, velour, fleece and jacquard
12+ t: Dyed per day; Soft-flow dyeing of knitted fabric across the group
500 kg: FabricMaster capacity; Benninger soft-flow machine commissioned March 2025
30%: Faster dye cycles; Versus our earlier setup — an extra batch every day

The make, step by step

Seven stages. One team accountable for all of them.

Most exporters buy fabric, cut it and hope. We knit the cloth, dye it, finish it, inspect it and only then cut — which is why a shade problem is ours to fix, not yours to chase.

01 Yarn in, fabric out

Knitting

We buy yarn and knit it ourselves into the constructions a style actually needs — single jersey, rib, interlock, terry, velour, fleece and jacquards.
- Around 30 circular knitting machines
- Single jersey, rib, interlock, terry, jacquard
- Yarn traceability by lot
02 Colour, right first time

Dyeing

Latest soft-flow machines bleach and dye the greige fabric. Only GOTS and OEKO-TEX approved dyes and chemicals go into the bath.
- Benninger FabricMaster soft-flow dyeing
- GOTS & OEKO-TEX approved dyes only
- Automated add-tank chemical dosing
03 Stable, soft, on-spec

Finishing

Stentering and compacting dry, heat-set and stabilise the fabric width — the step that controls shrinkage, hand-feel and appearance.
- Stentering, heat-setting and compacting
- Width and shrinkage control
- Softness and surface finish
04 Before a single cut

Fabric inspection

Every dyed lot is checked for colour consistency, GSM, width and strength before it is allowed anywhere near the cutting table.
- 4-point inspection
- Shade continuity across lots
- GSM, width and strength checks
05 Marker to bundle

Cutting

Lays are cut to marker and bundled by size and shade, so the sewing floor never has to guess which panel belongs to which garment.
- Marker planning for fabric yield
- Shade-banded bundling
- Panel checking before issue
06 Juki, Japan

Sewing

Flat lock, over lock and lock stitch machines — all Juki, all fitted with automatic thread trimming and dust collection.
- Flat lock, over lock, lock stitch
- Auto thread trim and dust extraction
- In-line checkpoints at every operation
07 Nothing leaves unchecked

Checking & packing

Final checking catches damages and measurement deviations. Garments are then pressed, folded and packed to the buyer’s carton spec.
- 100% final inspection
- Measurement and needle checks
- Buyer-specific folding and carton spec

Quality assurance

Six gates between yarn and carton.

Multi-stage inspection is the only reason a vertically integrated factory is worth more than a cheap one. Every gate below is documented and traceable to a lot.

01
Yarn in

Lot-wise yarn receipt, count and blend verification before knitting begins.
02
Greige audit

GSM, width and knitting-fault checks on the grey fabric roll.
03
Shade approval

Lab dip, bulk shade and continuity of shade across the full order.
04
4-point inspection

Dyed and finished fabric graded before it is released to cutting.
05
In-line checks

Operation-wise checking on the sewing floor, not only at the end.
06
Final audit

100% checking, measurement, needle and metal detection before packing.