Manufacturing

From yarn booking to the carton on your dock

Knitting, dyeing, cutting, sewing, decoration, quality control and packing sit inside one controlled workflow — which is how we hold quality and delivery dates together.

Manufacturing flow

Yarn to export, all in one factory

Every order follows the same seven stages, so you always know exactly where your programme stands.

  1. 01

    Yarn

    Combed, organic, Supima, bamboo, Tencel & RPET booked to your count.

  2. 02

    Knitting

    Single jersey, rib, interlock, loop knit and jacquard to your GSM.

  3. 03

    Dyeing

    Pantone-matched reactive, pigment and plant-based recipes.

  4. 04

    Cutting

    Computerised markers and band-knife cutting for clean yields.

  5. 05

    Printing

    Screen, DTF, sublimation and multi-head embroidery in-house.

  6. 06

    Packing

    AQL 2.5 audit, retail folding, barcodes and polybag or gift-box.

  7. 07

    Export

    FOB, CIF or door delivery with all documentation prepared.

Stage by stage

Eight departments, one accountable workflow

Each stage below runs inside our own units with its own checkpoints, so a correction never waits on an outside vendor.

Knitting at Evergreen Agencies, Tirupur
Stage 01

Knitting

Single jersey, interlock, rib, pique, fleece, loop knit and jacquard structures knitted to your GSM on circular machines, with fabric relaxed and inspected before it moves on.

  • 120–320 GSM range
  • Auto-striper & jacquard
  • 4-point fabric inspection
Dyeing & Processing at Evergreen Agencies, Tirupur
Stage 02

Dyeing & Processing

Reactive, pigment, garment and plant-based dyeing with lab dips approved against your Pantone reference, plus enzyme, silicone and bio-wash finishes.

  • Lab dips in 5–7 days
  • Non-toxic recipes
  • Shade continuity per lot
Cutting at Evergreen Agencies, Tirupur
Stage 03

Cutting

Computerised marker planning for maximum fabric yield, band-knife and straight-knife cutting, numbered bundling and shade-matched panel sorting.

  • CAD marker planning
  • Bundle numbering
  • Shade band control
Printing at Evergreen Agencies, Tirupur
Stage 04

Printing

Screen printing up to 12 colours, DTF, DTG, sublimation, puff, high-density, rubber and reflective prints — all produced and cured on our own tables.

  • Water-based inks
  • Strike-offs before bulk
  • Wash & rub testing
Embroidery at Evergreen Agencies, Tirupur
Stage 05

Embroidery

Multi-head embroidery for flat, 3D puff, chenille and appliqué work, with digitising and thread-shade matching included at no extra cost.

  • Free digitising
  • Thread shade matching
  • Caps, polos, hoodies
Quality Control at Evergreen Agencies, Tirupur
Stage 06

Quality Control

Inline checks at every operation, mid-line audits, needle detection and an AQL 2.5 final inspection before cartons are sealed.

  • Inline + end-line QC
  • AQL 2.5 final audit
  • Needle detection
Packing at Evergreen Agencies, Tirupur
Stage 07

Packing

Retail-ready folding, size stickering, barcode labelling, polybags, gift boxes and assorted ratio packing to your carton specification.

  • Barcode & size labels
  • Solid or ratio packs
  • Carton marking
Shipment at Evergreen Agencies, Tirupur
Stage 08

Shipment

FOB Tuticorin or Chennai, CIF and door-delivery terms with sea LCL/FCL, air freight and courier options, plus full export documentation.

  • FOB / CIF / DDP
  • Sea, air & courier
  • Docs handled in-house

Lead times & shipping

What to expect on dates and terms

Sampling
7–12 days for proto and fit samples
Bulk lead time
30–55 days after PP approval
Terms
FOB Tuticorin / Chennai, CIF, or door delivery
Modes
Sea LCL & FCL, air freight, courier for samples
Payment
30% advance, balance against documents
Audits
AQL 2.5 final inspection; third-party audits welcome