Our Manufacturing Process & Production Roadmap (The Path)
At Polos Inc, quality is not an afterthought checked only at the packaging table—it is engineered into every millimeter of yarn, dye bath, and seam stitch. Discover ‘The Path’: our transparent 7-stage manufacturing process governing how raw cotton is transformed into export-grade polo shirts and t-shirts inside our Tirupur facility.
Stage 1: Yarn Procurement & Combing
We source long-staple Indian cotton and process it through specialized combing cylinders to extract short fibers and impurities. We utilize 24s, 28s, and 30s counts to ensure high tensile strength and a lint-free foundation.
Stage 2: Precision Circular & Jacquard Collar Knitting
Knit on high-speed circular knitting machines into single jersey, double pique, and French terry. Simultaneously, computerized flat machines knit matching jacquard collars with reinforced tipping bands that will never curl.
Stage 3: Eco Soft-Flow Dyeing & Bio-Washing
Fabrics are dyed in low-liquor ratio soft-flow vessels using OEKO-TEX certified reactive dyes for 100% colorfastness. An organic cellulase enzyme bio-wash dissolves micro-fuzz, leaving the fabric velvety soft with zero pilling.
Stage 4: Computerized CAD Pattern Grading & Precision Cutting
Digital CAD marker planning maximizes fabric efficiency and guarantees millimeter-accurate cutting across all sizes. Fabric rolls relax for 24 hours prior to cutting to eliminate residual mechanical tension and post-wash shrinkage.
Stage 5: High-Speed Screen Printing & Tajima Embroidery
Apparel panels are branded prior to stitching: multi-color automated carousel screen printing (plastisol, water-based, discharge) and multi-head computerized Tajima embroidery for razor-sharp chest emblems.
Stage 6: Master Tailoring & Twin-Needle Assembly
Our 150+ artisan tailors assemble garments using Juki and Pegasus workstations: twin-needle bottom hems, reinforced shoulder-to-shoulder neck taping, bar-tacked side slits, and cleanly fused plackets.
Stage 7: AQL 2.5 Quality Inspection, Steam Pressing & Dispatch
Every completed garment undergoes 100% visual inspection, thread trimming, metal detector needle scanning, industrial vacuum steam pressing, individual poly-bagging, and secure carton packing.
Quality Control Gates at Every Production Stage
How our statistical process control ensures zero-defect delivery for high-volume enterprise orders:
| Production Stage | Quality Verification Gate | Standard Specification | Corrective Protocol |
|---|---|---|---|
| Raw Knitting | 4-Point Fabric Inspection | Defect score < 20 points / 100 sq. yards | Immediate roll rejection & loom recalibration |
| Dyehouse | Spectrophotometer Color Delta Check | Delta E < 0.5 under D65 daylight standard | Batch re-leveling prior to fabric drying |
| Fabric Curing | Washing & Shrinkage Test | Shrinkage < 3% length & width after 40°C wash | Compacting and stenter re-feed |
| Print & Embroidery | Cross-Hatch & Stretch Adhesion Check | Zero cracking on 100% fabric stretch | Flash cure temperature & squeegee adjustment |
| Final Assembly | AQL 2.5 Random Lot Inspection | Zero critical defects, < 2.5% minor allowance | 100% re-inspection of the entire carton batch |
Frequently Asked Questions — Our Manufacturing Roadmap
How do you guarantee that polo collars will not roll or curl over time?
We knit our collars on computerized flat-knitting machines with double-interlock jacquard construction and heat-set them at 180°C. This ensures the collar maintains a crisp, upright executive structure for over 50 washings.
Why do you allow fabric rolls to relax for 24 hours before cutting?
During knitting and dyeing, cotton fibers are placed under mechanical tension. By letting fabric rolls rest flat on unrolled tables for 24 hours, natural shrinkage occurs before cutting, guaranteeing that finished t-shirts retain their exact measurements after washing.
Can clients audit or inspect production batches in progress?
Yes. Corporate clients and third-party inspection agencies (e.g. SGS, Intertek, Bureau Veritas) are always welcome to conduct inline and pre-shipment inspections at our Tirupur facility.
How do I track my production batch?
Our dedicated account managers provide digital milestone updates with high-resolution photos at every key phase: knitting approval, dye lab dip matching, print strike-off, and final carton packing.
Experience Engineering Precision in Tirupur
Tour our production floor or discuss your apparel specifications directly with Founder & MD Sundar Thulasiraman today.