Fabric sourcing
Yarn and knitted fabric from Egyptian mills and partner mills abroad, through Aletex when the buyer prefers. Country of origin declared for all cotton. Better Cotton, organic and recycled yarn with transaction certificates.
Fabric in. Garments out.
Seven stages in one building, under our own supervision. Nothing is subcontracted, so nothing is untracked. Scroll and the floor draws itself.
Fabric inspection
Every incoming roll runs through the inspection machine. Defects, shade and weight are recorded against the roll number before it is released to the floor. A fault found here costs a roll. Found later, it costs an order.
Computerised cutting
Digital markers, automatic cutting heads, every lay logged with plies and consumption. Marker efficiency is known on the order, not estimated after it, and each cut bundle carries the lay number so any garment traces back to its rolls.
Sewing, sixteen lines
Sixteen lines running, thirty-three at full capacity. Each style has a full operation breakdown before the first piece is sewn, so the work content is known and hourly output by operation goes straight into the ERP.
Trims and labels
Neck labels, care labels, drawcords, eyelets, snaps, buttons and zips, sourced to the tech pack and pull-tested per batch. Woven and printed labels to your artwork, checked against the tech pack before they reach the line.
Print and embroidery
Rotary and continuous printing, screen and transfer work, and an embroidery department, all beside the sewing floor. A print run is a record on the same order, not an invoice from a third party.
Packing and dispatch
Final random inspection to the buyer's AQL, every garment through a calibrated metal detector inside a secured zone, then folded, bagged, labelled and packed to the carton ratio. Cartons are scanned at sealing and at loading.
What is on the floor.
Move over the plan. Each department names its equipment and what it records.
Fabric intake and inspection
Fabric inspection machine. 100% of rolls checked for defects, shade and weight. Records: roll number, mill lot, width, GSM, defect points, result.
Cutting
Computerised auto-cutting line with digital markers. Records: lay number, marker, plies, marker length, pieces, consumption per piece, rolls used.
Print and embroidery
Rotary and continuous printing, screen and transfer, embroidery heads. Records: run reference, colours, wash and crock test results.
Sample room
Dedicated sample development department for proto, fit, pre-production and shipment samples. Records: sample stage, comments, approval.
Sewing floor
Sixteen active lines, thirty-three at full capacity, with in-line inspection inside each line. Records: hourly output by operation, efficiency, faults with corrective action.
Final inspection and metal detection
Final random inspection to AQL, calibrated metal detector, broken needle policy, button and snap pull tester. Records: lot, sample size, defects by class, result.
Packing and dispatch
Folding, bagging, size stickers, carton ratios, scanning at sealing and loading. Records: carton number, size ratio, pieces, weight, lots, status.
Schematic layout, not to scale. Replaced by the measured plan when the factory supplies it.
How we take work.
CM
Cut and make. You supply fabric and trims, we cut, sew, finish and pack.
CMT
Cut, make and trim. You supply fabric, we source labels, drawcords, zips and packaging to your specification.
FOB
Full package. We source fabric and trims, produce, and deliver to port. Minimum 20,000 pieces per style, trial orders from 10,000.
