• Plot#D-56/A SITE Super Highway, Phase-1, Karachi 75350
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Quality Procedure

01

Warping and Weaving Quality Control

Objective: Ensure uniform tension and correct alignment of yarns for high-quality weaving.

Procedure:

  • Inspect the warping beam for proper alignment and tension of yarns.
  • Perform regular checks on looms to ensure proper functioning and correct pattern weaving.
  • Inspect woven fabric for defects such as broken threads, missed picks, or inconsistent pile height.
  • Record and address any weaving defects immediately.
Warping Machine
Warping Machine
Yarn Godown
Yarn Godown
Bobin Machine
Bobin Machine
Lab
Lab
Lab
Lab
Lab
Lab
Dyeing Checking Table

02

Raw Material Inspection

Objective: Ensure that only high-quality raw materials are used.

Procedure:

  • Inspect cotton bales for quality, ensuring they are free from contaminants and of the specified   fiber length.
  • Test samples for moisture content, staple length, and cleanliness.
  • Reject any bales that do not meet the standards.

03

Yarn Production Quality Control

Objective: Produce uniform, strong, and defect-free yarn.

Procedure:

  • Monitor the carding and combing process to ensure fibers are properly aligned.
  • Conduct regular checks on spinning machines for tension and twist consistency.
  • Perform tensile strength tests and check for yarn uniformity and absence of slubs or knots.
  • Document any deviations and take corrective actions.
Yarn In Bags
Yarn In Bags
Cone Winding
Cone Winding
Sizing Machine
Sizing Machine
Weaving Department
Weaving Department
Weaving Machine
Weaving Machine
Weaving Machine

04

Weaving Process Quality Control

  • Loom Setup: Inspect the loom setup to ensure correct tension and alignment of warp and weft threads.
  • Fabric Inspection: Check for weaving defects such as missing threads, uneven weave, or loose loops.
  • On-Loom Checks: Perform periodic checks on the loom to catch any issues early.

05

Fabric Finishing Quality Control

Objective: Ensure the final towel fabric meets the required softness, absorbency, and durability.

Procedure:

  • Monitor loop cutting and shearing processes to achieve the desired texture.
  • Test finished towels for softness, absorbency, shrinkage, and colorfastness.
  • Conduct physical inspections for any visible defects or inconsistencies.
  • Record test results and take corrective measures if any towel fails to meet the standards.
Inspection Table
Inspection Table
Towel Stacking
Towel Stacking
Towel Stacking
Greige Towels
Greige Towels
Length Hemming Machine
Length Hemming Machine
Soft Flow
Soft Flow
Soft Flow
Soft Flow
Soft Flow
Soft Flow
Dryer
Dryer
Dryer
Dryer
Dryer
Dryer
Dryer
Dryer
Finished Towel Dyeing
Finished Towel Dyeing

06

Dyeing Process Quality Control

Objective: Achieve consistent and vibrant colors that meet specifications.

Procedure:

  • Test dye batches for colorfastness, shade consistency, and adherence to specifications.
  • Maintain precise control over dyeing conditions (temperature, pH, time).
  • Inspect dyed yarns or fabrics for even coloration and absence of streaks or spots.
  • Document results and adjust dye formulations as necessary.

07

Stitching Cutting and Sewing Quality Control

Objective: Produce towels with clean edges and strong seams.

Procedure:

  • Inspect cut towel pieces for accurate dimensions and straight edges.
  • Monitor sewing machines for consistent stitching quality.
  • Perform pull tests on seams to ensure durability.
  • Inspect finished towels for any loose threads or improper stitching.
  • Document any issues and implement corrective actions.
Stitching
Stitching
Stitching
Final Inspection
Final Inspection

08

Final Inspection and Packaging Quality Control

Objective: Ensure that only defect-free towels are packaged and shipped.

Procedure:

  • Conduct a final visual inspection of each towel for any defects missed in previous steps.
  • Verify that labels are correctly applied and include all necessary information.
  • Inspect packaging for cleanliness and proper sealing.
  • Randomly select samples from packaged towels for a final round of quality tests.
  • Maintain detailed records of inspection results and any corrective actions taken.

09

Carton Packing

Objective: Safely pack the towels into cartons to optimize space and ensure stability during transport.

Procedure:

  • Arrange the packed towels neatly inside the carton, ensuring that the weight is evenly distributed to prevent the carton from tipping or becoming unbalanced.
  • Place heavier items at the bottom and lighter items on top to maintain stability.
  • Use cushioning materials (such as bubble wrap, air pillows, or paper fillers) around the towels to prevent movement during transportation.
  • Do not overfill the cartons; ensure there is a small gap at the top to allow for proper sealing.
  • Seal the carton using strong packaging tape (preferably reinforced or water-resistant tape) along all the seams.
  • Check the packed carton for proper sealing, labeling, and stability.
  • Arrange the cartons for shipment and prepare necessary shipping documents.
Carton Packing
Carton Packing
Container load
Container load
Carton Stacking
Carton Stacking

10

Shipment

The shipment procedure involves preparing packed cartons for transport, coordinating with logistics, and ensuring the towels reach their destination in perfect condition.

  • Verify Packing: Ensure all cartons are properly packed, labeled, and sealed according to customer and shipping requirements.
  • Documentation: Prepare necessary shipping documents, such as the packing list, invoice, bill of lading, and any required customs forms.
  • Schedule Shipment: Coordinate with the shipping or logistics company to arrange pickup and confirm shipment details, such as date, time, and destination.
  • Compliance: Ensure all shipments comply with local and international regulations, including customs requirements if shipping internationally.
  • Communication: Maintain clear communication with all parties involved, including the logistics team, carrier, and customer.
  • Risk Management: Consider insurance to protect against loss or damage during transit.

Conclusion:

The Quality Assurance Procedure in Towel Manufacturing is designed to ensure that each stage of the manufacturing process adheres to high standards, resulting in towels that are soft, absorbent, durable, and free from defects. By systematically inspecting and testing materials and products, documenting findings, and continuously improving processes, manufacturers can consistently produce high-quality towels that meet or exceed customer expectations.

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