From Fabric To Fashion: The Journey Of Garment Manufacturing
From Fabric To Fashion: The Journey Of Garment Manufacturing
Creating the masterpieces in Label Saasha manufacturing unit involves a complex series of steps. While the outcome is consistently admirable, it is necessary to have an understanding of how a fabric turns into fashion. Hence, in this blog, we will go through the entire process of garment manufacturing at Label Saasha.
From selecting textiles and processing fabrics to creating patterns and completing finishing touches, every step has its own importance. So, here is a step-by-step guide to our garment manufacturing process.
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Order Receiving
The manufacturing process starts with order receiving. Upon receiving the order, we initiate our pre-production process, which involves steps like fabric and trim sourcing, fabric selection, pattern making, and sampling. However, in order to reach all the later stages, the order received has to first be confirmed.
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Fabric Selection And Development
After we receive the order and finalize the client's design specifications, fabric sourcing and selection come into play. Fabrics usually fall into three categories: knitted, woven, and non-woven fabrics. They are manufactured in the textile mill and power loom sectors. We also have warehouses where we store fabrics. We carry on the selection of fabric based on quality requirements, such as color, fibre content, and texture.
During the fabric development phase, we communicate our requirements to the fabric supplier and negotiate pricing. Prior to bulk fabric ordering, we conduct fabric sample tests at our unit to check the quality. We take the client's feedback during the sample stage before the bulk order.
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Pattern Making
In this stage, we bring forward our technical experts. Pattern making is where our expert pattern masters break down the desired designs into 2D pieces. In other words, to make any kind of garment, we need a template for different body parts.These paper templates are patterns.
Pattern making occurs during prototype making, and we grade them during size-set sample making. However, to make things easier, our manufacturing unit uses CAD systems, which improve fabric utilization.
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Sampling
Before bulk production starts, it is very important to get the approval of our clients through garment samples. Sampling involves meticulously following the tech pack to prepare a prototype that adheres to all garment specifications and requirements. Here, we learn the garment details and requirements, which also involve research and development. Once our client approves of the sample, bulk production starts.
Our Sampling in 2 parts-
1. Before Order finalisation, we create rough samples as per technical files or reference given by designers
2. Final sampling of selected colour, embroidery, print and fabric after order finalisation.
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Production Planning
Once the sample has received approval, we start planning and scheduling all the processes and activities for the complete order. The production planning team at Label Saasha takes over such duties and controls the production activities. At this stage, the team prepares a time and action calendar.
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Cutting Process
The fabric is undoubtedly the most critical component in the entire production process in a textile industry. Almost 60 to 70% of the total cost of garment manufacturing is incurred in fabrics. Hence, to make maximum use of fabrics and minimise waste, we use advanced cutting machines for bulk cutting. Before the cutting process, the cut-order process is also planned out.
Some of the steps involved in the fabric-cutting process are as follows:
Fabric spreading: Here, we open the fabric rolls and spread them on a cutting table. Usually done by hand or with an automatic spreading machine.
Marking: Manual marking takes place by placing the paper patterns on the fabric and marking the outlines with chalk. Once done, the cutter follows the outline to cut the garment parts.
Laying: Laying is the process where we spread several fabric piles on the table and cut at the same time. It involves laying the fabrics one over the other, with larger pieces usually laid first, followed by smaller ones. Each lay has a unique number.
After all the steps, straight knife-cutting machines do all of the cutting. This is the most important step because after cutting the fabric, there is no going back. Hereafter, our workers sort the cut components by size and color. Next, bundling takes place, and they are sent to the stitching section.
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Printing And Embroidery
In this stage, we cater to any specific printing requirements requested by the client, which adds value to the garments. There are different ways of printing garments in our manufacturing unit. The most commonly used methods are hand block , screen printing Digital and heat transfer printing.
Label Saasha has expertise in a range of embroidery techniques and printing methods. For example, Suzani embroidery and block printing are among the popular processes we specialize in. .
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Garment Stitching
After the cutting and printing processes, we forward the cut components to the stitching sections. At this stage, sewing operators stitch and assemble the garment components to make the garment complete. Various sewing supplies are available in our sewing sections, such as threads, advanced sewing machines, industrial stitching machines, needles, trims, and more, to facilitate efficient production.
During stitching, we conduct rigorous quality checks to ensure every stitch meets our standards of excellence. This meticulous attention to detail in the stitching phase allows us to craft the garments with the utmost care and craftsmanship before they are sent to the finishing sector.
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Washing
Garment washing is an optional stage. It takes place if any apparel requires washing, such as denim, sweaters, etc. Washing takes place to remove any foreign particles, like dust and dirt. Other than cleaning, washing is also done to give the fabric a finished look.
At Label Saasha, we use industrial washing machines. Additionally, for garments that necessitate dry cleaning, such as suits, we have industrial dry-cleaning facilities available.
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Finishing Process
Before shipment, we finish all our garments. This includes meticulously removing any creases and wrinkles from the garments.
Below are some of the steps involved in the finishing process:
Thread Trimming: If the garments contain any uncut threads, they are cut and finished at this stage. We do manual as well as automatic trimming.
Pressing: Pressing is also included at this stage. Usually, we use a steam press to iron garment pieces. It helps give a fresh look to the garment.
Quality check: The pressed garments are sent through a proper quality check before folding. We conduct visual inspections to ensure precise measurements and flawless stitching across all garments. We also check the shade variations, labelling of sizes, and content labels of every garment at this stage.
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Folding And packing
In this stage, there are three key steps: folding, packing, and an internal audit.
Folding: The finished garments are folded to specific dimensions depending on the requirements of the garment. Once the folding is done, the price tags, hang tags, and other tags are attached to it.
Packing: The folded garments are then packed into eco-friendly and biodegradable bags to keep them in perfect shape. We also do carton packing to make transportation of the packed garments easier.
Audit: Once everything is complete, the packed items are audited by our team for quality assurance. Maintaining high-quality standards is paramount in our unit, as it directly contributes to buyer satisfaction.
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Shipment And Delivery
The last step is to ship the packed items to our client's specified locations. As per the production plan, the garments are dispatched for shipping. This is the end stage and marks the culmination of the entire garment manufacturing process.
Endnote
The garment manufacturing process is indeed a comprehensive production journey. However, even after the completion of all the production steps, we maintain ongoing communication with our clients to gather their feedback. Additionally, we conduct daily production reporting to track all activities and outcomes. By staying connected with our clients, we strive to uphold high standards of quality at Label Saasha.
Start your sustainable clothing brand with India’s leading clothing manufacturer
labelsaasha@gmail.com
Whtsapp- +91-9999676630
Namaste
Team Label Saasha
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