Production Technical Details: Crafting Superior T-shirts

 

As a leading T-shirt manufacturer and exporter in Bangladesh, our production process is meticulously managed to ensure every garment meets the highest international quality standards. We combine state-of-the-art technology with skilled craftsmanship to deliver precision and consistency for every order.

 

Fabric Sourcing & Quality Assurance

 

We begin with the careful selection and rigorous inspection of raw materials to guarantee the foundation of a high-quality garment.

 

Fabric Selection

 

We work with a diverse range of T-shirt fabrics to meet varied client demands:

• 100% Cotton: Combed, Semi-Combed, Carded; available in Single Jersey, Pique, and Interlock knits.

• Cotton Blends: Including CVC and TC.

• Performance Fabrics: Such as Polyester (e.g., moisture-wicking, quick-dry).

• Sustainable Options: Organic Cotton (GOTS certified options), Recycled Polyester.

• Specialty Blends: Viscose, Modal, and Lycra/Spandex blends for enhanced comfort and stretch.

 

Weight & Finishing Capabilities

 

• Weight Range: Typically from 120 GSM to 280 GSM (Grams per Square Meter), customized per client specifications.

• Dyeing & Finishing: Sourced from OEKO-TEX Standard 100 certified mills, ensuring environmentally friendly and skin-safe dyeing.

  • Dyeing Types: Reactive Dyeing, Pigment Dyeing, Garment Dyeing.

  • Special Finishes: Bio-wash, silicon wash, anti-pilling, moisture-wicking, anti-bacterial treatments.

 

Incoming Quality Control (IQC)

 

Upon arrival, all fabric rolls undergo stringent inspection:

• Fabric Inspection Systems: Utilizing 4-Point System or 10-Point System for comprehensive defect detection (e.g., holes, stains, weaving faults, shade variation, width consistency).

• Lab Testing:

  • Color Fastness Testing: In-house or third-party lab tests for wash fastness, rubbing fastness, and light fastness.

  • Shrinkage Testing: Pre-production tests to ensure the dimensional stability of the finished garments.

 

Precision Patterning & Cutting

 

Accuracy at these early stages is crucial for consistent garment fit and optimal material utilization.

 

Pattern Making & Grading

 

We leverage advanced technology for precise pattern development:

• CAD/CAM System: Utilizing Computer-Aided Design (CAD) software (e.g., Optitex, Gerber, Lectra) for highly accurate pattern creation.

• Digitalization: Converting physical patterns into digital formats for easy modification and archival.

• Grading: Professional grading of patterns across all required sizes (e.g., XS-XXL, kids' sizes) to ensure proportional fit.

 

Automated Cutting

 

• Fabric Spreading: Computer-controlled spreading machines ensure tension-free and accurate layering of fabric.

• Automated Cutting: High-precision CNC (Computer Numerical Control) or automatic fabric cutting machines (e.g., Lectra, Gerber) ensure uniform and precise cutting of multiple plies.

• Part Numbering: Individual cut pieces are meticulously numbered to maintain sequence throughout production.

 

Expert Sewing & Stitching

 

Our sewing lines are equipped with modern machinery and adhere to strict quality control protocols.

 

Advanced Sewing Machinery

 

Our facility boasts a comprehensive range of industrial sewing machines to handle diverse T-shirt designs:

• Single Needle Lockstitch Machines

• Overlock/Serger Machines (3-thread, 4-thread, 5-thread)

• Flatlock Machines (Coverstitch Machines)

• Specialized machines for operations like button attaching, buttonholing, and bar tacking.

 

Production & In-line Quality Control

 

• Modular Production Lines: Flexible lines optimized for efficiency, allowing for quick style changes and streamlined workflow.

• In-line Quality Control (IQC): Dedicated quality checkers are stationed at various stages to identify and rectify defects immediately, minimizing rework.

• Stitch Per Inch (SPI): Adherence to client-specified or industry-standard SPI for durable and aesthetically pleasing seams.

 

Embellishment & Finishing

 

We offer a range of decoration and finishing services to bring your T-shirt designs to life, followed by meticulous final checks.

 

Embellishment Options (Customize Based on Your Services)

 

• Screen Printing: Manual and Automatic Screen Printing machines (e.g., M&R, Roq) supporting Plastisol, Water-Based, Discharge, High-Density, Puff, Glitter, and Foil printing. Equipped with curing tunnels for durability.

• Embroidery: Multi-head Automatic Embroidery Machines (e.g., Tajima, Barudan) for precision, offering flat, 3D puff, and appliqué stitches.

• Other Techniques: Heat transfer, sublimation printing, or direct-to-garment (DTG) printing.

 

Finishing Processes

 

• Garment Cleanup: Thorough thread trimming and general garment cleaning.

• Ironing & Pressing: Steam ironing and vacuum pressing tables for a wrinkle-free finish.

• Garment Washing (If Applicable): Industrial washing facilities for specific washes (e.g., enzyme wash, silicon wash) to achieve desired hand feel and look.

 

Final Quality Inspection (FQC)

 

• AQL System: We conduct final inspections based on international AQL (Acceptable Quality Level) standards(e.g., AQL 2.5 or 4.0) to ensure compliance with client specifications.

• 100% Inspection: For critical orders, we provide full 100% garment inspection.

• Metal Detection: All finished garments pass through metal detectors to ensure the absence of broken needles or other metallic objects.

 

Packaging, Dispatch & Compliance

 

The final steps ensure your order is perfectly prepared for shipment, backed by our commitment to ethical and quality standards.

 

Packaging & Labeling

 

• Folding & Polybagging: Individual folding and packing into clear polybags with appropriate sizing stickers.

• Tagging: Accurate attachment of hangtags, price tags, and care labels as per client requirements.

• Carton Packing: Garments securely packed into export-worthy cartons, clearly labeled with style, size, quantity, and destination details.

 

Quality Management Systems & Certifications

 

Our operations are governed by international standards and ethical practices:

• ISO 9001: Adherence to international quality management system standards.

• Compliance Certifications: Strict adherence to social and environmental compliance standards such as BSCI, SEDEX, WRAP, OEKO-TEX Standard 100, and GOTS for organic products (if applicable).

• Lab Testing Capabilities: In-house lab for basic fabric and garment tests (2% shrinkage, spirality, GSM, color fastness).

• Third-Party Inspections: We readily accommodate third-party inspections (e.g., SGS, Intertek, Bureau Veritas) at any stage of production.

At NrB Fashion, we specialize in garment manufacturing and wholesale apparel supply, offering a wide range of high-quality fashion and promotional apparel, including

• Basic Apparel:
  White T-Shirts, Colored T-Shirts, Custom T-Shirts, Polo Shirts, Tank Tops
• Denim & Casualwear:
  Denim Jackets, Jeans, Shirt Dresses, Midi Skirts
• Specialty T-Shirts:
  Round Neck, Crew Neck, and V-Neck T-Shirts
• Promotional & Graphic Apparel:
  Printed Promo Wear, Custom Printed T-Shirts, Graphic Tees
• Loungewear & Homewear:
  Pajama Sets, Sleepwear, Rompers, Playsuits, Sleeping Gowns
• Seasonal & Knitwear:
  Sweaters, Pullovers, Woolen Garments, Fleece Shirts, Fleece Jackets
• Athleisure & Sportswear:
  Tracksuits, Jogging Suits, Shorts, Skirts
• Workwear & Outerwear:
  Overalls, Coveralls, Parkas, Jersey Jackets, Outerwear
• Private Label Production:
  Customized garments under your own brand label
• Men’s, Women’s, and Kids’ Clothing:
  Tops, Dresses, Blouses, Knitted Wear, Underwear, Boxer Shorts, Swim Shorts
• Accessories:
  Scarves, Troyers, Cap , Hat, Apron , organic shopping bag,and more