- Fabrics/ Fabric Mills
Most fabrics used in production of bags are made of 100% polyester or 100% nylon and fabric constructions such as Oxford and Rib Stop are common - some bags are also made of 100% cotton, T/C. PVC, PU and fabrics of other man-made fibers are also quite common. Choice of fabric depends on intended bag use, application, fashion etc.
We only buy fabrics from mills, which we have a longstanding relationship with. Most fabrics are sourced from Chinese fabric mills, and due to our large export volume we have achieved an excellent price/quality level. Most of the fabrics are made to match the buyers colour requirement. Sometimes buyers require a smaller quantity where we can use some standard stock colours and qualities and thereby offer the buyer a lower minimum per style and colour.
Some buyers require use of special fabrics, most of which are imported from Taiwan, Korea or Hong Kong. In some cases we have been importing fabrics from Europe.
- Cutting of Fabrics
Upon receipt of the fabrics from the fabric mill our factory will inspect the fabrics for any possible defects before production. When the order is scheduled for production the fabrics will be placed on the cutting table in layers. Markers made for each bag panel will be placed on top of the fabric pile and a handheld or fixed electric saw/layer cutter then cuts the fabrics.
Decoration of bags - being embroidery or printing - will take place before the bags reach the sewing lines. It is necessary for the fabric panels to lie flat on the embroidery machine or the printing table, which cannot be achieved if the bag is fully constructed.
For embroidery we use state of the art imported embroidery machines and printing is silkscreen printing using imported inks. The badge factories mostly use Taiwanese technology and equipment.
Our factories use a range of quality sewing machines such as BrotherMachines. The printed or embroidered panels will be passed to the sewing lines where they are being stitched together with other fabric panels, zippers, handles, badges and strips of Velcro into a fully constructed bag.
When the bags leave the sewing lines they will go to the assembling section where the remaining accessories will be mounted. If the bag requires a plate bottom it will be mounted here together with studs, if any. Other accessories such as hooks and snaps will be put on the bags here before they are passed to the quality control section.
- Quality Control
The bags are passed to the finishing section where the loose sewing threads will be cut off and the quality control section will inspect the finished products. Upon completion the bags will be transferred to the packing section. Though our factory has its own quality control section we have established an independent Quality Control Facility that performs a number of QC-checks in the beginning of the production as well as intermediate and final control. Our quality control standards are high and we meet the quality levels required by European, American, Australian and Japanese buyers.
We normally pack according to our buyers requirement and as such use no standard cartons. Most bags are packed in individual clear polybags and then bulk into strong 7-ply export cartons, which are manufactured in our in-house packaging unit (Shinpak Overseas Pvt. Ltd.) guaranteeing a safe transport to destination. As an option the polybags can be printed also.