|Production Process Flowchart|
Samples are continually designed and manufactured in-house by our weavers who produce new as well as timeless traditional patterns which are modified to suit the buyers taste. These are sent to the customers, who select and, if necessary, ask for modification of the designs and colours as per requirement. Customers, too send us designs created by their designers. Counter samples are manufactured on bit looms to match specifications.
On approval of the sample, the buyer places the order with us specifying the items, quantity, delivery, rate etc.
|Raw Material Purchase|
The actual production process begins with the purchase of yarn, chemicals and dyes from reputed suppliers who give us consistent quality and quick deliveries.
The yarn is then boiled in steam boilers to remove all impurities like cotton seeds and to increase its absorption capability.
|Bleaching and Dyeing|
Bleaching is then done to whiten and prepare the yarn for dyeing. The bleached yarn is then dyed by our experienced dyers using latest equipment at our new dyehouse using eco-friendly processes. We only use chemicals and dyestuffs specified and approved by the buyer. The bleached and dyed yarn is dried quickly in electro-mechanical dryers.
The yarn is then reeled onto bobbins and loaded on a warping shelf. Then depending on the reed and the design the warp yarn is mounted on the warp roll. Meanwhile the weft yarn is also reeled and kept ready for use by the weaver.
Depending on the design and number of colours, the looms are set with the correct number of pedals. The warp yarn is then passed through the reeds and the healds.
Now that the yarn is ready and mounted onto the loom, weaving is started by our experienced workmen who turn out quality handmade cloth. Between 2 to 30 metres of cloth is woven by a weaver depending on the complexity, width and the number of colours in the fabrics.
|Online Fabric Inspection|
The fabric is checked for defects on the loom itself for flaws like broken warps and other defects for immediate correction. The first metres are sent for inspection with a testing agency approved by the buyer, and to the buyer for final approval. To keep up the delivery schedule, we monitor the production day to day and add looms on noticing time lags, which would have caused delays if left unmonitored.
|Washing and Finishing|
The fabric is then washed, calendered, brushed or otherwise processed/finished as per the Buyer's instruction. We can also get fabrics coated with stain resistant coatings.
|Final Fabric Inspection|
Goods are then transported to our packing section and each metre of cloth is inspected for defects. Defective fabric, if any, is rejected immediately.
The fabric is then sent to the stitching units, where it is hand or machine cut depending on the designs. The cut fabric is distributed to tailors for stitching. The finished product is then trimmed and cleaned.
|Online Made up Inspection|
Our supervisors are continually inspecting the made ups while they are being stitched to rectify defects and faults to avoid rejection of the final goods. This ensures that rejection is minimal and allows us to give better value to our customers by avoiding wastage.
|Final Made Up Inspection|
Each piece coming out of the stitching unit is then inspected and in case there are any defects, they are either corrected or rejected. Special care is taken to ensure that foreign particles like needles etc. are not packed by mistake.
|Tagging and Packing|
The goods are then tagged and labeled as per the buyers instructions. Fabrics are packed in bales, each piece packed in a polythene bag, enclosed in a plastic film, covered with kraft paper, and finally covered with jute or HDPP. Made ups are packed in polythene bag, enclosed in a plastic film, covered with kraft paper, packed in cartons and finally covered with jute or HDPP. This extra care during packing ensures that goods are not damaged during transport to the clients warehouse. We also undertake specialised packing including ready to sell packaging in transparent plastic with price, bar code tagging as per the buyer's specifications.
|Documentation and Shipping|
Our staff then prepares the documents like Invoices, Packing lists required for shipping. Other certificates, if necessary are procured from the concerned agencies and attached to the documents before they are sent to the forwarding agents for shipping.
We feel that the consumer's response is of utmost importance for continued business. We, therefore regularly gauge the feedback from the client, and bring about changes needed in our products and systems.
Any quantity of yarn can be easily sourced form various reputed mills.
|Dyes and Chemicals|
Almost all major players in the Indian market have their dealers in Kannur and sourcing any quantity of dyes and chemicals is possible.
We can boil and dye yarn of approximately 1,000 Kgs. per shift. The quantity can be increased by additional shifts and other dye houses with whom we have regular arrangements.
We have 205 handlooms and 60 powerlooms under our direct control. This works out to around 70,000 to 100,000 metres of fabrics per month. The handloom industry is very flexible and we can easily bring in more looms under our supervision.
We have a capacity of 120 power machines. This translates to 40 to 50,000 pieces of Made ups per month. In addition, we can get made ups stitched with our associates in Cannanore and Bangalore to get more stitching capacity.
|Inspection and Packing|
We have experienced and efficient staff who can check and pack any quantity of fabrics and made ups as per the buyers specifications.