Production Process II
Finishing/Dyeing
"Color, temperature and time are precisely controlled
and documented in every process step."
Washing and Bleaching Line
Before color is applied to the fabric, it must be thoroughly prepared. In the washing and bleaching line, residues from production are removed that could affect even color absorption. The fabric passes through several washing stages using the counterflow principle: while the fabric moves forward, the water moves in the opposite direction, allowing resources to be used efficiently. All parameters such as temperature, pH value, water quantity and processing time are precisely controlled and documented. For light shades, an additional environmentally friendly bleaching process is carried out. This prepares the fiber evenly without placing unnecessary stress on it. The result is a clean, homogeneous fabric that forms a stable basis for the subsequent dyeing process and enables consistent color results.
Dyeing Process
The dyeing process depends on the material and fiber composition. Cotton fabrics are dyed using the cold pad-batch process. In this particularly economical and fabric-friendly method, the dye liquor is applied to the fabric without heat or salt, making the process highly resource-efficient, and is then fixed over a defined dwell time. During this phase, the dye bonds permanently with the fiber. To avoid external influences, the fabric is wrapped airtight. Fabrics containing synthetic fibers require a different dyeing method: in high-temperature jet machines, complete fabric batches are dyed at high temperatures so that the fiber opens and absorbs the dye. Both methods can be precisely controlled and enable reproducible color results, adapted to later wear, care requirements and intended use.
Stenter Frame
In the stenter frame, the fabric is aligned straight to the stitch direction and adjusted to its final width. It is dried and thermally fixed under controlled tension. This process stabilizes the fabric structure and ensures that stitch alignment and width are permanently maintained. In addition, finishes such as an easy-care finish can be applied to specifically improve care properties, feel and sewability. The stenter frame is a crucial step in preparing the fabric for garment production: it ensures that the fabric lies flat, can be processed evenly and retains its shape even after washing.
Fabric Inspection
In the sanforizing machine, the fabric is relaxed and compacted in a controlled manner. This targeted shrinkage significantly reduces later shrinkage values, while also improving the fabric feel and sewability. Here, the fabric is inspected using a camera system, and any defects are marked with labels for the next work step, cutting, so that they can be sorted out accordingly.
In addition, the fabric can be processed in the XETMA raising machine. There, special rollers gently pull fibers to the surface without separating them. This creates soft, voluminous surfaces, for example for brushed or fleece-like qualities. Both systems make it possible to adapt fabrics precisely to their later use and to produce different tactile properties in a technically reproducible way.
