Manufacturing
From yarn to finished piece.
Weaving, dyeing, printing and finishing under our own supervision — with the checkpoints that decide whether a lot ships or goes back.
The route
How a metre of cloth gets made
Seven stages, each with a sign-off. A lot that fails a checkpoint does not move to the next stage — it goes back or it is downgraded to seconds.
- 01
Yarn sourcing
Mulberry silk from Karnataka and West Bengal, long-staple cotton from Gujarat and Maharashtra, flax from certified European mills. Every bale is logged against the lot it will feed.
- 02
Yarn testing
Count, twist, strength and moisture regain checked on arrival. Off-spec yarn is rejected at the gate — it is far cheaper than rejecting woven cloth.
- 03
Dyeing
Reactive and vat dyeing for cotton and linen, acid dyeing for silk, and a separate natural-dye kitchen for the madder, indigo and pomegranate range. Lab dip approved before bulk.
- 04
Weaving
Jacquard and dobby powerlooms in Surat for volume constructions; handloom clusters in Varanasi, Kanchipuram, Bhuj and Bhagalpur for the hand-woven range.
- 05
Printing
Hand block printing on tables for the block range, rotary screen for repeat production, and digital printing for short runs and sampling.
- 06
Finishing
Washing, calendering, sanforising and stentering to hold width and control residual shrinkage before the cloth is rolled.
- 07
Inspection and packing
Four-point inspection on every roll, shade continuity checked against the approved standard, then rolled, poly-wrapped and labelled with lot, length and construction.
Quality control
What we measure before a lot ships
Fabric inspection
4-pointsystem
Colour fastness to washing
4–5grade
Colour fastness to rubbing (dry)
4grade min.
Residual shrinkage
≤ 3%
Width tolerance
± 1inch
GSM tolerance
± 5%
Capability
Constructions we run
| Fabric | Typical width | GSM range | Lead time (bulk) |
|---|---|---|---|
| Handloom cotton | 44 in | 110–160 | 15–21 days |
| Cotton voile / mulmul | 44 in | 60–90 | 10–14 days |
| Pure mulberry silk | 44 in | 60–120 | 18–25 days |
| Jacquard silk blend | 44 in | 120–180 | 21–28 days |
| Linen (60 lea) | 58 in | 140–190 | 15–20 days |
| Georgette / chiffon | 44 in | 50–80 | 12–18 days |
Dyeing and effluent
Colour, and what it leaves behind
Our finishing unit runs a primary and secondary effluent treatment plant with tertiary polishing, discharging within the Gujarat Pollution Control Board consented limits. Sludge is handed to an authorised TSDF operator.
The natural dye kitchen is deliberately kept separate. Madder root, indigo, pomegranate rind, myrobalan and iron liquor behave nothing like reactive dyes — different vessels, different water, different fixing times. Naturally dyed cloth is sold as such, with an honest note that the shade will move a little over its life.
Inside the mill
From the Weaving Floor
The constructions we run every week — jacquard silk blends off the dobby looms, handloom cotton from our cluster partners, and hand block printing on the tables at Palsana.
Capacity & lead times
Tell us your specification and volume.
Share fabric type, GSM, width and quantities — our production desk returns a costed capacity plan, with sampling, within one business day.