1. Incoming Material
Every month, our trucks unload hundreds of tons of textile industry waste and virgin materials from various factories at our production plant, for immediate processing.
2. Materials Sorting
The raw materials are then carefully sorted out according to their textures, colors and compositions. The selected batch is then processed according to the required production.
According to the requirements, the sorted materials are then fed into a four-stage tearing machine, which tears the yarns and fabrics apart into their initial stage of fibers, resulting in soft and fluffy fibers.
Stitch bonding technology / Needle punch technology
The fluffy fibers are led onto a moving ramp and combed in one direction in order to receive a smooth and even layer. Layers are placed one above another, according to the required thickness.
Next, depending on the required product, either a stitching pattern is applied to the fiber layers, or thousands of needles punch through the layers, to create the fabric. Special slitters are then placed along the roll in order to cut the fabric into the requested width.
Microfiber and other threads are knitted into many kinds of designed textures and jacquard patterned fabrics.
Final cutting, stitching and assembling
Each roll gets cut to the final length and is then stitched and assembled into the final shapes and dimensions, according to product specifications.
The final product is then packed in a wide range of standard as well as custom-made packaging. Bulk products can also be sent as is, or in pressed bales, to customers wishing to pack on their own.