Production

Sewing factory

      Today a sewing factory of JSC Tirotex is a modern plant including a complete technological cycle of treatment of finished fabrics and production of ready-mades in such a wide range as:

     Bed linen, flat and fitted sheets, pillow cases and duvet covers with buttons or zippers;

     Hospital and hotel assortment (bed sheets, pillow cases, duvet covers);

     Table assortment (table cloths, napkins, aprons, oven gloves, pot holders, etc.);

     Bed covers and towels with piping all around – made of waffle fabric;

     Hospital and working clothes (jackets, trousers, overalls, aprons, etc.);

     Home garments made of flannel and waffle fabrics (gowns, pajamas, suits, sauna sets, etc) ;

     Jersey garments for kids and adults (pajamas, night gowns, home and sports suits).

Sewing sections produce more than 250 models of ready-mades every month – it shows the mobility of production.

      A technological cycle of fabric treatment includes the development of model of product, technology of cutting and sewing, quality control conditions, issuing of normative technical documentation for production of goods, introduction of a new model to bulk production and, as a result, the production of qualitative product with optimal man-hour and consumption of raw material and resources.       

      The factory is constantly working on widening garments assortment: woman’s, man’s, kid’s and junior garments for home and rest, working clothes and hospital garments. They have got experience of production of outer clothing on the basis of European samples, for which not only esthetic but also hygienic and operational features are important. A distinguishing feature of Tirotex’ garments is multifunctionality, perfect appearance, safety and comfort. The staff of the factory is always in creation process: they use new technological methods, improve the quality of products which are of the greatest demands in home and international market.

      Sewing factory  -  is a strong complex consisting of 4 plant, each of them has a full production cycle:

          - section of quality control of finished fabrics;

          - section of quality control and cutting of fabrics;

          - section of automatic sewing lines;

          - sewing sections and packing department.

      Sewing sections are equipped with modern highly productive equipment: universal buttonhole machines of company "Brother", embroidery machines (continuous embroidering) of company "Tajima".

      Section of Quality Control of Finished Fabrics

      The main function of this section is to check the quality of finished fabrics and pack rolls of fabrics for export deliveries and home market.

      New modern machines for quality control were installed in 2008. Quality control machines are aggregated into one united complex with automatic gathering of information about the quantity and quality of fabric passed the control in a real-time mode. Rolls of fabric passed the quality control go to the packing automatic machine by a united transporter. The packing machine wraps rolls into polyethylene. Packed rolls are automatically sorted by articles, designs and colour variants and loaded into different carts.

      Besides quality control of fabrics intended for export deliveries or deliveries to the home market, the section prepares fabrics for the Section of Automatic Sewing Lines. The section is equipped with two special quality control machines, which make two processes at the same time: checking the quality of fabric and formation of  batches separated by widths, designs, colour variants for automatic sewing lines. This results in maximum efficiency during the production of ready-mades.

     Section of Quality Control and Cutting of Finished Fabrics

     This section is intended for cutting of finished fabrics. Fabric arrives from the Finishing Factory on carts without any preliminary quality control. Determination of quality level of fabric is carried out directly on the cutting table. Cutting of fabrics for production of ready-made products is carried out by two means: manual spreading of fabric layers and automatic spreading of fabric layers with width from 90 cm to 300cm. Cutting of fabrics for garments and jersey products is carried out by automatic cutting device allowing to provide high quality of cutting and productivity.

     Section of Automatic Sewing Lines

     A new section was built in the Sewing Factory in 2007 – it was a Section of Automatic Sewing Lines. The section is equipped with the most modern automatic sewing machines, in particular 3 lines for production of flat sheets, 2 lines for production of pillow cases, a line for production of duvet covers, a line for production of fitted sheets, a line for production of hospital sheets and a line for production of kitchen towels and table-cloths. Besides this, the section is equipped with 4 lines for folding of duvet covers, fitted sheets, pillow cases and towels. Vacuum turn-out machines are used for turning out duvet covers and pillow cases. Automatic folding lines for bed linen and vacuum turn-out machines shorten the time needed for the manual operations.

     Each automatic sewing line is a complex including almost the whole cycle of production of ready-made product. Such operations as quality control, cutting, sewing and folding of ready-made product are carried out simultaneously on such lines. Depending on the assortment, each automatic line is combined with folding machine, turn-out machine and packing table into a technological chain. Creation of technological chains allows to shorten the production cycle and minimize the time of waiting of half-made product at the next stage of treatment.   

      Section of Automatic Sewing lines includes also an Embroidering Section where 2 quilting-and-embroidering automatic machines (continuous quilting and embroidering from rolls of fabric) and 5 automatic embroidering machines for placed (piece to piece) embroidery.    

Application of embroidery and quilting on ready-made textile products allows to significantly widen the range of goods. Embroidery is used for bed linen, table linen, jersey items and home garments, as well as on hospital and working garments  in form of logo.

24-heads embroidering machines "Tajima" (Japan) for continuous embroidering can make any design on fabric.

     Sewing Sections and Packing Department

     When the Section of Automatic Sewing lines is intended for production of big amount of standard models of bed linen and table linen, a sewing section is used for production of more complicated models of bed linen and table linen, hospital garments and working clothes, jersey items.

     Decorative elements are used for decoration of bed and table linen – pping with cords, decorative stitching Rimoldi, scallops, hem-stitching, elements of quilting and embroidering.

     When sewing hospital and working clothes they use special equipment – 2-needle machines for joining the parts with “lock” stiching, 4-needle machines for preparation of shoulder-straps, 2-needle machines for preparation bolt loops; bar-tacking machines, machines for preparation and attaching of patch pockets.

     There are special sewing lines for production of jersey items – they are equipped with modern special machines. As a decorative treatment of jersey items they use such a decorative stitching as “croshet” and bundling of edges, as well as placed print.

     Packing Department makes individual packing of ready-made textile products into polybags and boxes. And it is a very important part of production cycle. Only careful hands of packers can make any item look maretable.

     In 2007 Tiotex implemented a Section of Automatic Sewing Lines of Swedish company AKAB.
     A Section of Automatic Lines is the most modern, powerful, economical and productive complex where manual sewing is completely replaced by automatic production, at the beginning of which we have just a roll of fabric and at the end – ready-made product. One of important parameters here is the time spent for production of goods starting from the moment when fabric is put onto the automatic line, and finishing with the first piece of ready-made product – not more than 15 minutes. A commom manual production usually takes from 3 to 5 days. It is time which is spent for manual production, storing, transportation from one section to another one.

     It took Tirotex just one year to learn AKAB complex. Exactly this time was needed to increase the productivity of this section by 21 times and start producing more than one million meters of ready-mades per month.
     Today the section includes 8 automatic sewing lines, 4 automatic folding lines, 4 lines for manual sewing and embroidering section. Existence of such a section allows the company to widen the range of ready-made textile products, increase the volume and conclude new contracts.