Sewing Department capabilities
The heart of our garment construction. Our sewing floor operates 12 structured assembly lines equipped with high-speed Japanese and German sewing technology, managed by skilled operators.
1. 12 High-Speed Assembly Lines
Our sewing floor layout is optimized for modular efficiency, enabling both high-volume basic runs and high-complexity design drops:
- Modular Line Configurations: Lines are calibrated by industrial engineers to streamline components assembly (sleeves, collars, body joins) and reduce handling time.
- Diverse Machine Operations: Equipped with Juki single-needle lockstitch machines, Brother overlock machines (3, 4, and 5 thread), and Pegasus flatlock machinery.
- Specialty Auto-Setters: Computer-controlled automated pocket setters and buttonhole-making/sewing stations ensure structural uniformity across all items.
2. Specialized Knit & Activewear Construction
We employ dedicated sewing technology for stretch fabrics to guarantee structural integrity:
- Four-Needle Six-Thread Flatlocks: Essential for activewear, compression wear, and athletic leggings. Flatlock seams sit flat against the skin, avoiding chafing while providing 100% stretch recovery.
- Elastic Attachment Machines: Computerized tensioners feed waistband elastic evenly, preventing bunching or uneven waist fits.
3. Inline Quality Inspection Checkpoints
Quality is checked at every workstation rather than solely at the end of the line:
- Workstation Audits: Operators run measurement gauge audits on their own output before passing components to the next station.
- Line QC Stations: Inline inspectors check sub-assemblies (such as neck band attachments or armhole join stitching) under standard D65 lightbox illumination, identifying sewing variances instantly.
Daily Machine Calibration: Every needle is logged, and machine tensions are calibrated daily for the specific fabric weight (GSM) and thread type to avoid puckering or skipped stitches.