Production Process I
Knitting
Modern circular knitting technology makes it possible to control stitch patterns precisely and produce fabrics with a uniform structure and reproducible quality. Every production step is technically monitored:
Yarn path, stitch density and machine parameters are continuously checked. This turns individual threads into a durable fabric that does not develop by chance, but is deliberately constructed.
Knitting therefore lays the foundation for all subsequent processes and has a major influence on the fit, feel and durability of a garment.
"We permanently keep around 200 tons of raw fabric
in stock across all qualities"
Yarn
Yarn is not a neutral raw material, but a technically defined material. Composition, fineness and twist determine how stitches are formed, how elastic a fabric is and how it reacts to subsequent finishing. In knitting, the yarn is fed with uniform tension via creels and guided steadily into the machines through yarn guide systems. A smooth yarn flow is essential for an even stitch pattern and prevents disruptions in the production process. Yarn therefore forms the technical basis for reproducible fabric quality.
Circular Knitting Machine
Large circular knitting machines turn yarn into a textile surface in continuous operation. Thousands of needles work simultaneously and create stitches with consistent precision. The fabric is usually produced as a tube, which already gives it a high level of basic stability. Sensors continuously monitor the process: if a thread breaks or the stitch pattern changes, the machine stops automatically. This allows faults to be detected and limited at an early stage. The combination of industrial performance and technical control enables uniform fabric production, where quality is not corrected afterwards, but created from the very beginning.
Santoni
On Santoni machines, textiles are produced without side seams directly in their later shape. Size, structure and elasticity are already defined during the knitting process. Cuffs are also knitted directly onto the garment and are not attached with a seam. Each piece leaves the machine almost finished, eliminating additional processing steps. This method is particularly suitable for close-fitting products where comfort, even stretch and a clean surface are essential. The fully automated process ensures a high level of repeatability and enables precise control of product properties – from the first thread to the finished textile.
Fabric Storage
After knitting, the fabric is first wound into fabric rolls as tubular fabric. These rolls are weighed, labeled and clearly marked. Each batch remains traceably documented and can be assigned to its origin at any time. In the fabric storage area, the unopened fabric rolls are systematically stored and made available for the next processing steps. This structure ensures transparency, planning reliability and a consistent material flow within production.
Slitting Machines
Before further processing in finishing, the knitted fabric is opened. Special slitting machines cut the fabric tube in a controlled manner. The cut is not simply made straight, but also at a calculated angle depending on the requirements. This technique reduces later twisting of seams, a known issue with knitted cotton fabrics. The process was developed by an Italian machine manufacturer specifically for this purpose. The opened fabrics are then passed directly on to finishing, where they are dyed and finished.
Once the fabric has been knitted and opened, the step begins in which it receives its functional properties. In finishing, the textile raw material becomes a fabric that combines color, stability and care properties.
