How we process your fabrics?

Fully integrated production facility: 25,000 sq ft spanning three buildings, 100 sewing machines, 40+ weaving looms, dye house with 8-10 vats, screen and digital printing equipment, in-house embroidery digitization, testing lab. 100+ skilled professionals handle design, weaving, dyeing, printing, stitching, embroidery—all in-house. No outsourcing to external vendors. Why this matters: most Karur competitors fragment production (weaver handles fabric, dyer handles color, printer handles design, stitcher handles assembly). Each hand-off introduces delays, communication gaps, quality disputes. Our timeline is 30-45 days because it's one team managing one pipeline.

Process built for custom manufacturing. Minimums start at 200 units per SKU (competitors require 1,000+). Samples in 5-7 days, bulk production 30-45 days. Each step has quality gates: materials tested before production, colors checked after dyeing, prints inspected before seaming, stitching verified during assembly, final visual inspection before packing. Defects caught and fixed immediately. One batch fails inspection, the team doesn't move it forward. No surprises at shipment.

Design

Custom fabric designs created in-house using CAD software and manual sketching. Clients specify: colors, weave patterns, dimensions, material (cotton %, fiber blend), weight (GSM). Our design team digitizes concepts and produces prototypes for approval. Sample turnaround: 5-7 days for standard fabrics in existing colors, 10-15 days for custom colors or patterns, 15-21 days for complex designs combining embroidery + printing + custom colors. Design revisions handled same-day (in-house digitization avoids vendor delays). No per-revision charges for bulk orders.

Weaving

40+ looms operate simultaneously for custom fabric production. Capacity range: 180-500 GSM depending on end-use (kitchen linen ~400 GSM, table linen ~280 GSM, living linens ~220 GSM). Yarn sourcing: we purchase from regional suppliers and test incoming materials for weight, shrinkage, strength before weaving. Quality gate during production: every loom monitored for tension, thread alignment, density. Finished fabric inspected for defects. Custom weave turnaround: 7-10 days (including yarn setup and testing). In-stock fabrics in common weights available for immediate transition to dyeing/printing. Most competitors own fewer looms, so custom weaves get queued; we have capacity for parallel orders.

Dyeing

In-house dye house: 8-10 vats for batch dyeing and color matching. We match custom Pantone colors from 100+ color library (standard base library + spot mixes). Process: immersion dyeing for solid colors (fabrics fully immersed, rotated, temperature-controlled). Each batch tested for color fastness (IEC 60105-B02 standard: fade resistance in wash and light) and shrinkage (multiple hot-water cycles). Wastewater management: zero-discharge on-site treatment system (all effluent treated before discharge). Quality gate: batch fails fastness or shrinkage test, fabric stays in production until it passes. Lead time: 5-10 days for custom color formulation (formulation, test dye batch, fastness testing, final batch if approved). In-stock colors (20+ standard hues) available same-day to next-day. Most competitors outsource dyeing; we own the equipment and color expertise.

Printing

Two capabilities: screen printing and digital printing. Screen printing handles 1-4 color designs on towels, bags, linens. Minimum 200 units per SKU (screen setup cost absorbed by us). Turnaround: 5-10 days (screen exposure, ink curing, inspection). Digital printing handles full-color photographic designs (no setup cost per design, ideal for complex or multi-color graphics). Minimum 200 units per SKU. Turnaround: 10-15 days (digital file prep, test print, color matching, full production). Quality control: every print batch checked for ink adhesion (no ruboff), color accuracy (vs approved sample), coverage (no gaps). Test print approved by client before full batch production. Most competitors offer one or the other; we offer both with in-house capability.

Stitching

100 industrial sewing machines for hemming, seaming, finishing, binding. Line capacity: kitchen linen, table linen, bed linen, living linens, bags (multiple product types running in parallel). Standard finishes: single-ply hemstitching, double-stitched seams, reinforced stress points (handle attachment, corners). Specialized finishes: quilting, pleating, bias binding, satin binding. Quality control at each station: thread tension verified (prevents weak seams), seam strength tested mid-production (not just end inspection), finish quality checked (no skipped stitches, consistent hemlines). Defects caught and corrected by operator during production. Stitching turnaround: 5-10 days for standard items, 10-15 days for complex finishes. Most competitors run single-product lines; we run multiple product streams simultaneously.

Embroidery

In-house digitization (CAD-based, no outsourcing) and machine embroidery (60+ machines dedicated to embroidery). Services: logos (company names, symbols), text (monograms, custom text), custom designs (combinations of multiple colors and stitches). Complexity tiers: 1-color simple logos add 10-15 days to lead time; multi-color embroidery adds 15-20 days; monogramming (individual text on each piece) adds 5-10 days per 500 units. Minimum per design: 200 units. Quality control: test embroidery approved by client before full batch production. Design revisions handled same-day by in-house digitization team (no vendor delays). Cost: embroidery adds ₹50-100 per unit depending on complexity; we absorb all digitization fees (no per-design charges for bulk orders). Most competitors outsource digitization, which adds delays and per-revision charges.

How Sourcing Works

Inquiry

Share your requirements: product category (kitchen linen, table linen, baby products, bags), target specifications (fabric type, weight, colors, prints, embroidery), estimated volume (200-5,000+ units), timeline (when do you need it?). We'll provide an initial quote within 24 hours. No obligations; we're answering your specific needs, not pushing generic catalogs.

Sample Development

We produce samples matching your specifications end-to-end: custom color (if needed), custom weave pattern (if needed), custom print or embroidery design, same stitching as bulk production. Samples delivered in 5-7 days for standard products, 10-21 days for complex customization. You inspect, approve, or request revisions (revisions handled same-day, no extra cost). Only after sample approval do we commit to bulk production.

Costing & Terms

Pricing based on: product type, volume, customization (color, print, embroidery), fabric sourcing costs (raw material prices fluctuate quarterly). Minimum order: 200 units per SKU. Payment terms: 50% advance, 50% on shipment (standard for international orders; LOCs available for 10,000+ unit orders). Lead time confirmed once specifications finalized. We'll send formal quotation with exact pricing, delivery date, payment instructions.

Production

Full production run using in-house weaving, dyeing, printing, stitching, embroidery. Timeline: 30-45 days for standard products, 45-60 days for custom colors/prints, 60-90 days for complex customization or large orders 5,000+. Production happens on your timeline; we don't batch multiple clients' orders into shared runs (you're not competing for loom time). Quality gate at every step: materials tested, colors verified, prints inspected, stitching verified before moving to next stage.

Quality Control

Final 100% visual inspection plus durability testing (color fastness, shrinkage, seam strength). Any batch that fails testing doesn't ship—we rework it until it passes. Third-party inspectors available (Intertek, SGS, Bureau Veritas) if your buyer requires independent certification. Every order includes detailed inspection reports (defect rates, test results) before shipment.

Shipment

Export-ready packaging (protective wrapping, labeled cartons), documentation (commercial invoices, packing lists, certificate of origin), freight options (FCL—full container load, LCL—less than container, air freight). Incoterms available: FOB (you arrange freight), CIF (we arrange freight), DDP (delivered to your door). Lead time to port: 2-5 days after quality sign-off. Ocean freight: 20-35 days depending on destination (Asia/Europe/Americas). We handle all export documentation in-house; you receive ready-for-import shipments.

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