Growing cotton is not an easy process; it requires sunny & warm weather, plenty of water and is harvested in dry weather. It is planted in early spring and after several months the flower buds turn to pods which blossom into fluffy cotton ‘bolls’.
Once the cotton is harvested by hand or machine, it then gets sorted into bins for the next process to take place, this step is called ‘ginning’. Ginning separates lint (cotton) from the seeds which is then sent in for testing. The seeds collected from ginning often get sent to extract cottonseed oil.
Spinning is used to turn ginned cotton into yarn. The machinery creates slivers of consistent thicknesses which then creates a very thick rope of fiber. After twisting, yarns are wound onto bobbins which is then ready for the knitting process to start.
During the knitting process, spun yarn is turned into cloth by pulling loops (stitches) through one another. To achieve superior quality, cotton is circularly knit, creating a seamless tube for the body. There are three types of knitting in the TShirt making process: jersey, interlock & rib.
Dyeing a plain knitted fabric is done by putting it into a slow flowing dyeing machine, which needs to have the right combination of water, chemical colours and the ideal temperature. The quality of the dyeing chemicals, as well the spun process affects the overall colour quality.
The cloth must now be ‘finished’ in order to wash out any particulate matter, bleach or dye and to establish a consistent colour. Finishing also shrinks the fabric as much as possible, and softens it to prevent any holes from being created during the sewing process.
The cutting process involves cutting the bodies and sleeves out of the tubes of fabric received from the finisher. Fabric is cut several stacks at a time using modified jigsaws. The cut bodies and sleeves are then tied together and sent for sewing. Ribbed fabric for collars is also cut during this phase.
8. SEWING: This is the last and most labor-intensive stage of TShirt construction. The cut bodies, sleeves & collars are sewn by a seamstress using an array of sewing machines to attach each piece via a batch assembly line. TShirts are then inspected for any defects and are either repaired or removed.
To obtain the best possible print we use the Best Quality T-Shirts and the Latest DTG (Direct to Garment) printers.
10. TEE OFF:
After all these processes are complete, the final T-Shirt is sent to our customers (I mean who doesn’t wear T-Shirts?).