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Iris Factory services
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SPINNING
SPINNING

Spinning involves a series of machines that turn compacted, ginned cotton into yarn. The compacted bale is first beaten and picked, to loosen the cotton into a more manageable state. It is then carded to straighten and smooth the ginned fibres into a sliver - an even, consistent rope.

KNITTING
KNITTING

During the knitting process, spun yarn is turned into cloth by pulling loops, called stitches, through one another. To achieve superior quality, cotton is circularly knit, creating a seamless tube for the body. Circular knitting is accomplished by cylinder knit machines. Because this knit method creates a tubes without side seams, it requires a separate tube of cloth be knit for every garment size.

DYEING
DYEING

After the cloth is knit, it must be ‘finished’ to wash out any particulate matter, bleached or dyed to a consistent colour, pre-shrunk to international standards and finished to give a soft hand feel. Some fabrics are bleached white with hydrogen peroxide during the preparation process.

CUTTING
CUTTING

The cutting process involves cutting the bodies and sleeves out of the tube of fabric received from the finisher. Our state-of-the-art automatic cutting machines are used to ensure fast and accurate cutting of garments. Fabric is typically cut several stacks at a time with modified jigsaws, allowing for a large number of pieces to be created simultaneously. The cut bodies and sleeves are then tied together and sent for sewing. Ribbed fabric for the shirt collars is also cut for each body size during this phase.

SEWING & DISTRIBUTION
SEWING & DISTRIBUTION

Sewing is the last step in the construction of the shirt, and is the most labour intensive. After receiving the bodies, sleeves, and collars from the cutter, the machinists use an array of sewing machines to attach each piece via a batch assembly line. Once the garments have been made up, they get quality checked, folded, packed and sent to our customer.