BS Apparel based in Tiruppur is one of India’s largest organic cotton Bamboo Apparel manufacturer. Organic cotton Bamboo apparel are soft, elastic and absorbent. It has natural anti-bacterial properties.
How are Organic Cotton Bamboo Apparel Manufactured?
Organic cotton Bamboo apparel has all the four properties. Mositure wicking, anti-fungal, anti-bacterial and easy-to-wear. It gives comfort in summer as well as in winter.
Organic Cotton Bamboo fabric is ideal for performance based sports wear.
Turning bamboo into sportswear requires the complex knitting of thousands of threads. It short it takes one of these; a circular knitting machine! First they mount more than 3000 bobbins of bamboo cotton on a metal frame called a creel.
Bamboo cotton is ideal for producing lightweight strong fabric but for the rigors of the sport field this weave needs a little more strength. The answer is to add elastane to the loom, a synthetic fiber that’s known for its durability and elasticity.
Americans call elastane spandex. As the knitting machine spins threads of bamboo cotton and elastane are drawn through the eyes of dozens of needles. The needles move from side to side interlocking bamboo and elastane threads and knitting them together. An hour and half later the machine has knitted almost 100 meters of stretchy bamboo fabric.
And after a light box inspection for any flaws, the batch is ready for dyeing which is an art in itself.
So now the clothing manufacturer calls on the services of the expert fabric and dye processors. Their first problem is that the different threads in this weave have different properties. Bamboo fibers absorb dyes faster than cotton fibers. This is due to the natural waxes in the cotton that repel water. The solution is to pre-heat the fabric before dyeing.
First it’s loaded into one of the four soft flow machines, each capable of processing 1000 kgs of fabric. Then workers add caustic soda. Sometimes used as a drain cleaner, caustic soda is highly corrosive. It gradually scours wax and impurities from the cotton fibers until they are able to absorb liquid. The number of seconds it takes fabric to absorb water is known as the absorbency time and after two hours in the machine the absorbency time of the bamboo cotton fabric has been reduced from 40 seconds to one.
It takes six hours for the bamboo and cotton fibers to absorb the dye. Fully saturated the fabric comes out in the intended color. But right now these 30 kgs rolls of bamboo cotton fabric are a long way from a shirt. They are returned to the clothing company where they are unrolled and loaded into a spreading machine. After being marked out, 25 layers of cloth are ready for cutting. Using a selection of lethal industrial cutters each shirt is a fabric jigsaw of at least five different panels. They sort each cut panel according to its size and tie the pieces for a shirt in a bundle ready for assembly.
A workforce of 280 workers produce 6000 shirts a day and a different sewer is responsible for constructing each part of the garment. With the final seams over locked and reinforced the zipper and collar are attached. Finally the label and logo are added before the bamboo cotton shirts are pressed, wrapped and ready for the shops. The bamboo’s journey from forest to sports field is complete.
INFRASTRUCTURE
Knitting
This is where the yarn is converted into knitted fabric for garment manufacturing.
The knitting process is even more elaborate with the circular machines, which knit with the utmost precision and flawlessness to give you exquisite fabrics.
Sewing
The latest sewing equipments such as overlock machines, flat seamers, bar tacking machines, zigzag machines and many more see to it that the order is done perfectly right down to the last stitch.
Cutting
Their garment designers create the patterns using computers, equipped with latest garment designing software.
Production Development
In house design studio with qualified designers looking out for worldwide fashion trends that is successful in the global markets as well as meeting customers’ design requirements.
Central Warehousing
Materials like Yarn, Fabric, Accessories & Garments are stored in our efficiently designed ware house, which ensures easy traceability & better storage for materials.
BS Apparel
Manufacturer of Organic Cotton Bamboo Fabric
No: 25, SIDCO, Mudalipalayam,
Tirupur – 641606. INDIA.
+91-421-2374399
http://bsapparelindia.com/index.html
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