Knitting is a technique for producing a two dimensional fabric made from a one-dimensional yarn. To produce knitted fabric of supreme quality, it is imperative that superior quality raw material is procured at competitive prices. At Velsten Apparel we ensure procurement of finest quality yarn in the market, some of its portion outsource and 70% + is produced in-house for our knitting facility. We can produce knitted fabrics in any volume from smaller to larger quantities subject to order and our client’s requirements. A wide range of fabric weave and structures we are capable of to produce in-house like Jersey knit, Elastane knit, L. PQ, Lycra PQ, Honey comb Pique, Interlock, Terry, Fleeces, Low Shrinkage Fleeces, Jacquards, Ottoman, stripers in feed, auto and engineered combinations.
Apparel Manufacturing Journey
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Infrastructure
To produce quality goods, and that too on time, you need a good production facility, capable of taking on any challenge thrown at you. In this regard, Velsten Apparels possesses the best infrastructure that has the ability and potential to give you quality products. Our manufacturing process has been vertically integrated to facilitate all the processes involved in garment manufacturing under one roof. This enables us to reduce the time spent in competing your orders. All our machines are the latest available in the market, and whenever required Velsten Apparels has never shied away from purchasing the most modern equipment’s. All our divisions are equipped with the latest equipment’s to maintain the high quality standards that we have set for ourselves.
SPINNING
Pakistan is 4th largest cotton grower and has more than 442 spinning mills. Spinning is the process of twisting together of single strands of fibers to form yarn, and is a major part of the textile industry. Velsten has strong collaboration with farmers and ginners invested in growing of cotton. The company would ask the growers to sow the most suitable cotton variety for knitted products. Our strong collaboration and partnerships with ginners helps us to pre-book whole year raw cotton requirements according to orders booking. This backend raw material, helps us to provide the consistent quality products for our customers throughout the year. If the customers want to lock the prices for a certain period, Velsten Apparel can offer this service as we reserve the cotton for the particular program.
KNITTING
DYEING
Dyeing is the application of dyes or pigments on textile materials such as fibers, yarns, and fabrics with the goals of achieving color with desired color fastness. Dyeing is normally done in a special solution containing dyes and particular chemical material. At Velsten Apparel we well understood how integral it is for product quality that’s why our collaboration with compliance certified dye houses having a production capacity of around 1,16,295 Kg of dyeing / day allows us to fully meet our valued client’s production requirements. Our commercial dye houses have latest fabric dying machines for dyeing of cotton fabric and a fully computerized high temperature jet-dyeing machine to dye all kinds of synthetic fabrics including polyester.
FINISHING
Fabric finishing is the key processes to comply testing protocols according to ASTM testing parameters defined by clients / brands. The core parameters are setting up the fabric shrinkage, heat-setting of the Lycra blended fabrics and hard pressing with application of silicone softener chemicals to achieve the premium look of finished fabrics. Fabric finishing setup at our compliance certified facilities, comprises of automatic hydro-extractors for the removal of moisture from dyed fabric, computerized dryers for instant fabric drying, and calendaring machines for systematic soft-setting and rolling of fabric, fully computerized compaction machines for complete shrinkage control, and panel wash machines and tumble dryers for panel washing the fabric to give minimum shrinkage value.
CUTTING
In Textile garmenting, cutting is the process in which we cut of the pattern into pieces from specified fabric for marking garments. Using the markers made from graded patterns and in accordance with the issue plan, fabrics are cut to prepare garment assembly. Our cutting unit is well equipped with latest machinery including Gerber Plotter, Auto Spreader, Auto cutter, Band Knife, Spreader, Bierrebi etc. Our computerized cutting system is capable of achieving more widespread use as technology costs decrease labor cost and giving us edge to remain competitive in our pricing as well as meet the daily production targets. Our computer driven automated cutters utilize vacuum technology to hold stacks of fabric in place while cutting as cutting blades are sharpened automatically.
Embellishment
Since 2009, Velsten Apparel has been providing factory direct apparel solutions to a number of distinguished clientele. We work with clothing lines and brands, both the young startup brands and the well-established private labels. Our in-house screen printing, embroidery, direct to garment, direct to film transfer, sublimation and vinyl cutting equipment’s enable us to supply large number of garments on demand with quickest lead-times. We work with corporate customers to deliver the highest quality apparel merchandise and employee Workwear. We offer our customers apparel customization services from design to distribution, keeping every step in between under one roof and in one place. Our in-house anciliary equipment’s make us capable to embellish 5,000 to 5,500 pieces per day.
STITCHING
This is the main assembly stage of the production process, where sewers stitch fabric pieces together, and a garment is assembled. We have installed computerized sewing machines that can be programmed to sew a specific number of stitches to perform a standard operation, such as setting a zipper or sewing a collar. With over 150+ stitching machines, 300+ skilled and expert operators empower us to achieve more than 0.5 million garments annually contributing annual turnover of approx. 2 Million USD in our export portfolio. Adding support of Quality control and Quality Assurance departments are in place to make sure the company’s objective of zero defect. Computerized Bar coding and Back Track systems provide Velsten 100% predictability and tracking performance.
LAUNDRY
Laundry department at Velsten Apparel comprises of automatic and turbo load washers. The laundry process is done at above and below the room temperature to increase the activities of any chemicals used and the solubility of stains. The benefit of the garment dye process is no shrinkage. If the t-shirt fits right the first time you put it on, it will fit right for as long as you own it. This is because the fabric has been commercially washed and dried twice. Also, garment dye typically results in a softer feel and richer color. Garment dyeing entails colouring clothes after they’ve been cut and sewn. Ordinarily, fabrics are woven and dyed by the roll, but if you make up a shirt or suit first and then apply the dye, this softens both colour and texture, giving new pieces the rumpled elegance of vintage.
QUALITY LAB
Our well-equipped quality lab is the backbone to ensure quality checks at every production stage. We follow stringent quality checks at every stage of manufacturing starting from Raw Cotton, Yarn, Fabric, Processing, Cutting, Stitching and Packing. Before the fabric is cut, it is checked whether it conforms to the customer’s standards of shrinkage, finished g/cm2 etc. After each lot of fabric is cut, 100% cut parts inspection is conducted to ensure that only good quality pieces move to the stitching units. We well understood the cost of quality and have quality checks at every production process that helps to avoid reworking on a garment especially re-testing of performance of apparel to save cost and time and remain competitive with 100% quality assurance guaranteed.
Leader in Custom Cut & Sew Apparel
As a garment manufacturing company, our first step is to fully understand what you are trying to do. Whether it is a badge, a clothing design, an industrial product, or something else, we make sure we have a clear idea of what you need. With a team of more than 10+ passionate designers and merchandisers, we can develop a wide range of industrial products to meet your growing market needs! Everything you need to create at your new line of products. We create projects, develop tech packs, produce samples, prepare offers and manufacture your products. We are providing you these services under one roof by ensuring topnotch zero defect custom quality product.