We are one of the leading manufacturing, buying and exporting houses in India. Having recognized the difficulties faced by international importers in perceiving the super-fine quality apparels with the minimum costs, Polestar Garments has begun to help them in offering the apparels with the expected quality and cost range to the international customers.
Manufacturing Services
You design it, we deliver it!
Our team is efficient in providing satisfactory services to our international buyers.
Step 1
Sampling
Sampling is a process of making a product prototype prior to starting bulk production. Sampling is one of the main processes in Garment Industry and it has a vital role in attracting buyers, because the buyers generally place the order after they are satisfied with the quality of the samples.
Sampling includes details like a product/style code or a reference number, color specifications, kind of fabric, composition, description, quantity, and details of embroidery, buttons, zippers, or any other sort of accessories used. Hence it can be said that sampling works as a bridge between buyers and manufacturers. Once the sample is satisfactory to the buyer, the buyer will confirm the order.
Step 2
Order Confirmation and BOM
Once the sample is satisfactory to the buyer, the buyer will confirm the order and issue the purchase order (PO) with the necessary tech-pack, which includes all the information such as i) Measurement Chart, ii) Size ratio, iii) Fabric composition, GSM, Fabric Color, iv) List of trims and accessories required, and v) Delivery date.
Once the purchase order is received, we need to estimate the consumption of fabric and trims per garment for the whole order. And accordingly we need to make a Bill of Materials (BOM). Bill of Material is a list of raw materials needed to be sourced to make a garment and make it ready for shipment as per buyer’s requirement. A BOM normally includes items description, consumption (per piece consumption) with a defined unit of measure, projected cost per unit and total cost of each item.
Step 3
The Process of Fabric Making
Yarn
Process
Once the BOM is made, we need to order the yarn in accordance with the total fabric consumption for the order. The yarn production is nothing but the harvested processed raw materials are transformed from raw fibers into yarn. This is done by spinning the fibers. Weaving and knitting are different methods to prepare otherwise intertwining to form textile fabrics. They are made from both natural and synthetic fibres.
Knitting
Process
After the raw materials have been converted into yarn, they are now ready for the second step in the production process, which involves joining these individual threads together to form fabric. It is a method by which yarn is manipulated to create a fabric. With different yarn count, fiber type, needle size, and stitch type, we can make a variety of knitted fabrics such as single jersey fabric, interlock, fleece, pique, etc.
Dyeing
Process
A dyeing process is the interaction between a dye and a fibre, as well as the movement of dye into the internal part of the fibre. A dyeing process involves adsorption (transfer of dyes from the aqueous solution onto the fibre surface) and diffusion. While dyeing we should take enough care to make all the dyeing-related processes correctly so as to ensure that the fabric color lasts long for many wearings and washings.
Compacting
Process
Once the fabric is dyed, the fabric has to go through a process called ‘compacting’.
i) To control the shrinkage of the fabric
ii) To maintain the GSM of the fabric as required by the buyer
iii) To control the overall width of the fabric (DIA)
iv) To iron the fabric (to give a good finishing to the fabric, making it free from the wrinkles)
Fabrics
Washing
Garment washing modify the appearance, outlook comfort ability and fashion of the garments.Washing technique creates new fashion such as tagging, grinding, destroy, blasting, permanent wrinkle, deep dye, tie dye, hand crapping, etc. The different types of washing are Normal wash, Pigment wash,Caustic wash,Enzyme wash, Stone wash, Super white wash, Bleach wash, Acid wash,Silicon wash, Soft wash.
Fabrics Relaxation
Fabric Relaxation
The fabrics are relaxed from its roll type tie in the cutting room natural temperature. Relaxation is very important and has to be done before cutting to get fabric’s own shape. The objective of fabric relaxation is to keep fabrics dimensional stability before cutting into garment. Relaxation is necessary for stretch fabrics. Relaxation machines are also used to relax knitted fabrics.
Step 4
Fabric Inspection and Cutting
Because the material is continually under tension throughout the various stages of the textile manufacturing process including knitting, dyeing, and other finishing processes, we should relax the fabric to shrink so that further shrinkage during customer use is minimized.
After the fabric has been relaxed, it is transferred to the spreading and cutting area of the garment manufacturing facility. The fabric is first cut into uniform plies and then spread either manually or using a computer-controlled system in preparation for the cutting process.
Next, garment forms—or patterns—are laid out on top of the spread, either manually or programmed into an automated cutting system. Lastly, the fabric is cut to the shape of the garment forms using either manually operated cutting equipment or a computerized cutting system.
Step 5
Value Addition (Printing, Embroidery, etc.)
Value addition is the process where we enhance the garment by adding some incentives to it. For example, a buyer may ask for his brand logo embroidery on the garment. In such case, the cut-panels are given for these processes before they go for stitching. There are some exceptionally value additions which are done on the fabric once the entire garment is stitched such as garment-wash.
Here are some of the value additions done on the fabric before stitching:
Printing
Process
It is a process of reproducing text and images, logos or motif as required by the buyer. (All-over prints, Chest prints, etc)
Embroidery
Process
Embroidery is the art or handicraft of decorating the fabric with some image of text with needle and thread
Applique
Process
Applique is an ornamental needlework in which pieces of fabric in different shapes and patterns are sewn or stuck onto a larger piece to form a picture or pattern.
Sequins
Process
A small piece of a shiny ornamental disc made from plastic or colored metal foil, often sewn on cloth or used to decorate the garment.
Heat-transfer
Stickers
A transfer sticker is created by cutting sticker material to a shape, graphic or text, and then removing the background and then attached with the garment with a particular heat and pressure.
Closureand Fasteners
Closures are functional trims used to open or close a garment. Some of the closure types are zippers, buttons, snaps, elastics, hooks, loop tapes.
Step 6
Stitching/Sewing
Stitching or sewing is done after the cut pieces are bundled according to size, colour and quantities. Garments are sewn in an assembly line, with the garment becoming complete as it progresses down the sewing line. Sewing machine operators receive a bundle of cut fabric and repeatedly sew the same portion of the garment, passing that completed portion to the next operator. For example, the first operator may sew the collar to the body of the garment and the next operator may sew a sleeve to the body.
Quality assurance is performed at the end of the sewing line to ensure that the garment has been properly assembled and that no manufacturing defects exist. When needed, the garment will be reworked or mended at designated sewing stations. This labor-intensive process progressively transforms pieces of fabric into designer garments.
Step 7
Checking, Ironing, Packing
Fabric checking is used to measure the quality level of the incoming fabric.
It is realistic to assume that however well checking or quality control procedures operate within a factory there will always be a certain percentage of garments rejected for some reason or other. The best way to carry out quality checks is by
-
Establishing a standard as a criterion for measuring quality achievement.
-
Production results can be measured and compared to the planned quality standard.
-
Corrective measures to be carried out if there are any deviations in the plans.
So there will be a team of quality checkers checking each and every garment. After a garment is fully sewn and assembled, it is transferred to the checking section for final checking of the garment.
This team not only identifies manufacturing defects but also looks for cosmetic flaws, stains, or other spots on the garment that may have occurred during the cutting and sewing processes. Spots are often marked with a sticker and taken to a spot-cleaning area where the garment is cleaned using steam, hot water, or chemical stain removers.
Ironing is necessary to smooth away unwanted creases and crush marks.
After a garment is fully checked and approved, it is transferred to the ironing section of the facility for final pressing. Ironing is nothing but to make the garment free from wrinkles and to give a better appearance and perfect finishing to the garment.
Packing includes the activities of producing the container for a product and packing.
Ironed garments are folded in a specified dimension. Tags, such as price tags and hang tags are attached to the garment by means of a kimble gun or threads. Finally, properly folded garments are packed into poly bags as per customer’s requirements. Individual poly bags are then packed into bigger cartons.
The strength of our organization rests on the following factors. With these factors we are able to assist our customers with satisfactory services. The factors are:
Step 8
Final Inspection
Once the packaging is completed, there will be a final inspection for the mass production. The packed garments are then inspected for quality assurance of the outgoing finished products. This process is followed for internal quality audit and to ensure that no defective garments are packed into the cartons.
The quality inspector collects samples from the whole inspection lot according to the standard sample size. The inspector only checks sample size items and detects defects and defective units from the sample size. We strictly follow AQL2.5 for quality measures.
In the AQL standard chart, it is defined that up to how many defective garments can be accepted. If the inspector founds more defective units (defects) in the sample size units than the acceptable limit, the whole lot will be rejected.
Step 9
Shipping
If the inspection result is a pass, then the garments are ready for the shipment and ready for the end consumer. The documents team will prepare the documents required for customs clearance and shipping and then the cargo will be shipped through sea or air as per the buyer’s requirement.
The strength of our organization rests on the following factors. With these factors we are able to assist our customers with satisfactory services. The factors are:
Quality
The availability of fabric suppliers with super-fine quality.
Partnership
Our partnership with leading manufacturing companies that supply us with defect-free apparels.
Team
Efficient team that clearly understands the requirement of the customers so as to manage the buying and exporting processes to the satisfaction of our customers.
Time
Maintenance of pro-active approach towards the defect identification and taking the corrective measures to ensure timely deliveries.
Price
Flexible and competitively priced.
Network
Chain of networks in ordering, manufacturing, buying and exporting with ease.