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.

Stages
4
Processes
8
Outwork
0
Stage 01 / 04

Dye

Cotton, polyester and spun polyester, taken to your reference and held until you pass the dip.

Your reference · Rust
ProcessMonthly output
Dyeing90,000kg
Package dyeing in progress: a carrier of dyed yarn packages on the hoist above two pressurised kiers, with the dosing lines and control panel behind.
Fig. 01 · The dye houseIn-house
Stage 02 / 04

Knit and weave

High speed automatic braiding — at this scale, the first in Pakistan. Belt and gallus woven to width on the same floor.

ProcessMonthly output
Draw cord6,000,000m
Twill tape3,000,000m
Jacquard100,000m
Webbing belt300,000m
Gallusnot estimatedPending
The braiding hall from above: rows of high-speed braiding machines running the length of the floor, each with its bank of bobbins.
Fig. 02 · The braiding floorIn-house
Stage 03 / 04

Finish

Silicon, PVC, metal, plastic and rubber tips on computerised machines. Eyelets set and plated.

ProcessMonthly output
Tipping5,000,000pcs
Eyeletingnot estimatedPending
Finished draw cords and flat tapes laid out in rows, each with a moulded tip on the end, in a range of colours.
Fig. 03 · Tipped endsIn-house
Stage 04 / 04

Check and pack

Checked piece by piece, not by sample, then counted into cartons with a packing list.

ProcessMonthly output
InspectionEvery piece
PackingPer carton
The checking floor: cord being checked by hand and tied into tagged hanks at inspection benches, with cartons stacked along the wall.
Fig. 04 · The inspection tablesIn-house
Cartons out

Approved in the dye house. Still right in the carton.

Packing listCarton 01
Shade
Rust, as approved
Inspection
Every piece
Packing
Per carton
Made
Lahore · no outwork

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.

Request shadeSee the shades we have run
Lab dip 1 · On test
Dip 1 matches in daylight.Now switch the light.

Illustration · screen colours are simulated

  1. 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.

  2. 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.

  3. 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.

  4. 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.

StageProcessMonthly output
01DyeDyeing90,000kg
02Knit and weaveDraw cord6,000,000m
Knit and weaveTwill tape3,000,000m
Knit and weaveJacquard100,000m
Knit and weaveWebbing belt300,000m
Knit and weaveGallusnot estimatedPending
03FinishTipping5,000,000pcs
FinishEyeletingnot estimatedPending
04Check and packInspectionEvery piece
Check and packPackingPer carton
10 lines · 8 confirmed · 2 pendingPending means not confirmed, and not estimated
Quality & compliance

Each certified by an independent body. Ask for any certificate and we send it.

Request a certificate
ISO 9001:2015Quality managementVerify OEKO-TEX® 100Harmful substancesVerify GRSRecycled standardVerify Higg FEMEnvironmental moduleRequest Higg FSLMSocial and labourRequest

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.

Send enquiry
+92 320 4166000WhatsApp