Process
Yarn in one end, cartons out the other
One building, one payroll, one set of records. Nothing in this sequence is subcontracted, which is why a shade that was approved in the dye house is still right in the carton.
Four stages · eight processes · no outwork
Footage of this stage has not been published yet.
Stage 01
Dye
Cotton, polyester and spun polyester, matched to your reference and approved as a dip before anything runs.
- Dyeing
- 90,000 kg
Footage of this stage has not been published yet.
Stage 02
Knit and weave
High speed automatic braiding — at this scale, the first in Pakistan. Belt and gallus woven to width on the same floor.
- Draw cord
- 6,000,000 m
- Twill tape
- 3,000,000 m
- Jacquard
- 100,000 m
- Webbing belt
- 300,000 m
- Gallus
- Pending
Footage of this stage has not been published yet.
Stage 03
Finish
Silicon, PVC, metal, plastic and rubber tips on computerised machines. Eyelets set and plated.
- Tipping
- 5,000,000 pcs
- Eyeleting
- Pending
Footage of this stage has not been published yet.
Stage 04
Check and pack
Checked piece by piece, not by sample, then counted into cartons with a packing list.
- Inspection
- Every piece
- Packing
- Per carton
Shade matching
How a colour gets approved before anything runs
Dyeing is stage one, so a shade that is wrong is wrong in every stage after it. This is the sequence that stops that happening, and it is the same one on every order.
Step 01
You send a reference
A TCX number, a physical swatch, or a piece of previous production. A screen grab is not a reference.
Step 02
We dye a lab dip
In our own dye house, on site. 90,000 kg a month of capacity, so your dip is not queued behind a bulk run.
Step 03
It is assessed under controlled light
D65 in a lighting cabinet, cross checked under TL84 and incandescent. Metamerism is caught here, not on your floor.
Step 04
You approve it in writing
The approved swatch is retained here, so a repeat is matched to the same physical standard, not to a memory.
Capacity
What the building does in a month
Every figure below is monthly output for the process beside it. Where a line says Pending, the number has not been confirmed and is deliberately not estimated.
| Stage | Process | Monthly output |
|---|---|---|
| Dye | Dyeing | 90,000 kg |
| Knit and weave | Draw cord | 6,000,000 m |
| Knit and weave | Twill tape | 3,000,000 m |
| Knit and weave | Jacquard | 100,000 m |
| Knit and weave | Webbing belt | 300,000 m |
| Knit and weave | Gallus | Pending |
| Finish | Tipping | 5,000,000 pcs |
| Finish | Eyeleting | Pending |
| Check and pack | Inspection | Every piece |
| Check and pack | Packing | Per carton |
Quality & compliance: ISO 9001:2015, OEKO-TEX® 100, GRS, Higg FEM, Higg FSLM.
Tell us what you need it for
Send a specification, a shade reference, or a photograph of the trim you are replacing. We will tell you what we can run and by when.