Registering the Design
The completed screens are then fitted into the press. A system of clamps and screws allows for very minute adjustments to the position of the screen. If the design features only one colour, then the screen must simply be straight, if there are two or more colours, the design must be registered, or lined up perfectly. Screens are generally made with cross-hair registration marks to aid in this process.
Because of the special print process we use, our shirts are garment dyed after printing. Though there are many dye methods available, paddle dye tubs are used because of their ease of operation and maintenance.After dyeing, the shirts are inspected and shipped to the customer.CotC shirts are dyed with low-impact, bi-functional reactive dyes, offering superior wash hand light-fastness in addition to their low environmental impact.
The first step of the production process is to draw a shirt pattern on a large paper. Next, the fabric is overlaid in layers according to the number of orders. Then, the large patterned paper is laid on top of the fabric and the fabric is cut according to the pattern. Later, the cut pieces are inspected by our experienced Q.C. staff to ensure the fabric quality.
Printing the Shirt
The next step is to fit the shirts onto the press. Ink is poured into the screen, which is "flooded"---completely spread with ink. The ink is scraped across the screen with a squeegee with enough pressure to push it through the mesh in the stencil area. For a multicolour design,the shirt is dried briefly before a second colour is printed to avoid smudging.
Packing & Bundling
The individual pieces are pressed by steam presses to remove any wrinkle marks and packed in the carton boxes. After packing, they define the level of different shirts. Then, In carton boxes, they arranges the shirt pieces in accordance to the buyers order that one carton’s will fill up 10 pieces of long gents & ledis T-shirt, 20 pieces of short & middle gents shirts.
Drying & Ironing the Shirt:
When the shirt is washed it is taken off the machine and put through a conveyor-belt dryer to set the ink. In between colors of a multicolor design, a flash dryer is used to allow the shirt to be dried while it is still on the press and also it need to be ironed. In the case company after washing there is thread cleaning section followed by ironing.
For pacing folding must be needed. If they do not folding the shirt, they can’t packing this.
Then different pieces are included in different no by shapping or cutting size-Middle, Long,Short, Extra large, etc.
For cleaning products need to be washed, so that any spots or germs are removed and products are shown shining.
Sewing is the most important step in the actual construction of the shirt itself,and is the most labor-intensive.After receiving the bodies, sleeves, and collars from the cutter, the sewers use an array of sewing machines to attach each piece via a batch assembly line. Sewing Department consists of 2 sections:Sewing Section – In this section, cut pieces of fabric are sewn together and inspected for sewing quality before passing to assembly section.Assembly Section - Responsible for assembling shirts and measuring the size. If the shirts are in required sizes, they will later be processed in a thread vacuum machine to remove the remnants of thread..