Manufacturing
Yarn
Every garment is decided here, before a single stitch.
Cotton and organic cotton yarn is received, tested and staged against the fabric specification it is committed to. Getting the input right is the cheapest quality control there is.
Both organic and conventional cotton are run through the same line, kept segregated end to end so certified organic output stays traceable.
Knitting
Fabric is made in house, not bought in.
Yarn is knitted into jersey and its variants on the company's own machines. Owning fabric formation is what makes the rest of the line predictable, because the cloth arrives at cutting already to specification.
A dedicated bank of knitting machines feeds the process house directly, with no external fabric procurement step in between.
Dyeing
Colour is a measurement, not a judgement.
Greige fabric is dyed inside the process house. Recipes are prepared by a digital dispenser rather than by hand, so the same shade is reproducible across a repeat order months later.
A digital dispenser system prepares colour recipes automatically, removing manual weighing from the critical path.
Processing
Where fabric becomes stable enough to cut.
Dyed fabric is finished to its target hand, width and dimensional stability. This is the stage that decides whether a garment still fits after it has been washed.
Modern dyeing, printing and finishing equipment operates as one continuous house rather than as separate outsourced steps.
180,768sq ft under one roof
Printing
Graphics applied at garment scale.
Chest prints and all over graphics are screen printed on site. Keeping print in house means a print rejection is caught within the same building as the fabric that caused it.
A large screen printing setup handles chest printing alongside the embroidery floor.
Embroidery
Applied decoration without a subcontractor.
Embroidery runs as an internal department, sized to absorb the decoration load of the garment programmes it serves rather than to a separate outside schedule.
Modern embroidery machines operate as a large in house setup, integrated with the sewing programme.
Cutting
Precision at the point of no return.
Patterns are plotted and graded on CAD, fabric is spread mechanically, and lays are cut on automated tables. A cut panel cannot be un cut, so this is where automation earns its place.
Pattern CAD plotting and grading, automatic spreader machines and automated cutting machines run as one sequence.
Sewing
The stage that is still, correctly, human.
Panels are assembled into garments on sewing lines. Machinery sets the tolerance; the operator sets the quality. Both are why infant garments hold up to the way infant garments are actually treated.
Sewing lines are equipped with current generation machinery across a centrally air conditioned floor.
Quality
Nothing leaves on the assumption that it is fine.
Finished garments are inspected and passed through needle detection. For clothing worn by infants, metal contamination is not a statistical risk to be managed. It is a defect to be physically excluded.
Needle detector machines verify product safety, and a spectrophotometer reads colour electronically for transmission to the customer.
Packing
Ready for a port, not just for a shelf.
Passed garments are packed and staged for despatch. The site sits near Kochi with access to both sea and air freight, which is what makes an export share above eighty percent workable.
Packing and despatch complete the line that began with yarn intake in the same complex.
80.72%of turnover exported
