Loom to home
Follow one thread
Six stages, about eleven days, and roughly sixty kilometres of travel between five towns. Scroll to follow a single thread from bale to box.
Yarn sourcing
Long-staple cotton is bought in Kandhla and graded by hand for staple length and neps before a single bobbin is wound. We reject roughly one lot in six.
Weaving
Pit looms for handloom lines, shuttleless rapier looms for percale and sateen. A double bedsheet is about 9,600 picks of weft — four hours on a pit loom.
Dyeing
Reactive dyes at controlled temperature, then four rinses. Effluent goes to a common treatment plant, and every batch recipe is logged so a colour can be repeated a year later.
Cutting & stitching
Cut in stacks against steel templates, then stitched at eleven stitches per inch with a four-inch top hem. Most stitching happens in job-worker homes within twenty kilometres.
Quality check
Four-point fabric inspection, a dimensional check after a test wash, colour fastness at grade 4 or better, and a final look at every hem. Rejects go to seconds, never to export cartons.
Packaging
Folded on a jig to a fixed size, wrapped in a cotton pouch rather than plastic, labelled with HSN, GSTIN and batch, and cartoned for the courier or the container.
Eleven days later