Production Process I
Knitting
Modern circular knitting technology allows stitch structures to be controlled precisely and fabrics with a uniform structure and reproducible quality to be produced. Every production step is monitored technically:
Yarn feed, stitch density and machine parameters are continuously checked. This turns individual threads into a fabric that does not develop by chance, but is built up in a controlled manner.
The knitting department therefore lays the foundation for all subsequent processes and has a significant influence on the fit and feel of a garment.
"We permanently keep around 200 tonnes of raw fabric
across all qualities in stock"
Yarn
Yarn is not a neutral raw material, but a technically defined material. Its composition, fineness and twist determine how stitches are formed, how elastic a fabric is and how it reacts to subsequent finishing processes. In the knitting department, the yarn is fed at a consistent tension via creels and guided reliably into the machines through dedicated guiding systems. A smooth yarn feed is essential for an even stitch structure and helps prevent disruptions during production. Yarn therefore forms the technical basis for reproducible fabric quality.
Circular Knitting Machine
Large circular knitting machines continuously turn yarn into a textile surface. Thousands of needles work simultaneously to create stitches with consistent precision. The fabric is generally produced as a tube, which already gives it a high degree of basic stability. Sensors monitor the process continuously: if a yarn breaks or the stitch structure changes, the machine stops automatically. This allows defects to be identified and contained at an early stage. The combination of industrial performance and technical control enables uniform fabric production in which quality is not corrected afterwards, but created from the very beginning.
Santoni
Santoni machines produce textiles without side seams directly in their later shape. Size, structure and elasticity are already determined during the knitting process. Ribbed cuffs and hems are also knitted directly into the garment rather than being 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 allows the product properties to be controlled precisely – from the first thread to the finished textile.
Fabric Storage
After knitting, the fabric is initially wound into rolls as tubular fabric. These rolls are weighed, labelled and clearly identified. 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 stored systematically and made available for the subsequent processing stages. This structure ensures transparency, planning reliability and a consistent flow of materials throughout production.
Slitting Machines
Before the fabric moves on to finishing, the knitted fabric is opened. Special slitting machines cut open the tubular fabric in a controlled manner. Depending on requirements, the cut is not simply made in a straight line but can also be made at a calculated angle. This technique reduces the later twisting of seams, a known issue with knitted cotton fabrics. The process was developed specifically for this purpose by an Italian machine manufacturer. The opened fabrics are then passed directly on to the finishing department, where they are dyed and finished.
Once the fabric has been knitted and opened, the stage begins in which it receives its functional properties. In the finishing department, the raw textile material is transformed into a fabric that combines colour, stability and care properties.
