Today’s Garment Factory of Tirotex is a modern production facility including a complete technological cycle of treatment of finished fabrics and production of finished articles.
A technological cycle of fabric treatment includes the development of new types of finished articles, cutting and stitching technology, elaboration of quality control standards, normative and technical documentation, putting new styles into mass production and, as a result, high quality production of new items, based on optimal consumption of labour costs, raw materials and resources.
The Garment Factory is a complex of 4 sections, each having a complete cycle of production:
• the section of fabric quality control (for finished fabrics);
• the section of fabric quality control and cutting;
• the section of automatic sewing lines;
• sewing shops and the packing section.
The section of fabric quality control (for finished fabrics)
The main function of this section is a quality control of finished fabrics and packing of fabrics intended for export delivery or sale in the local market.
New modern equipment for quality control was installed in this section in 2008. Quality control machines are combined into one complex machine, collecting data (such as quantity and quality of fabric inspected) in an automated real-time mode.
After passing the quality control, the rolls of fabric are transported through the conveyor belt to the packing machine where they are automatically wrapped into polyethylene film. Packed rolls of fabric are automatically sorted by type, designs and colourways, and then are loaded onto special carts.
Besides inspection of fabrics intended for export delivery or local market, this section is responsible for inspection and preparation of fabrics, which are used later for production of ready-made articles. The section of fabric quality control is equipped with two special quality control machines, which are used both for quality control and sorting of fabrics by widths, designs, colourways before they are brought to the sewing shop. It guarantees maximum efficiency.
There is a doubling machine in this section (wide fabrics with width from 150 cm to 300 cm are double folded by this machine). This type of packing is of great demand among many customers from domestic and export markets because it is suitable for transportation and storage of fabrics.
The section of fabric quality control and cutting
Fabrics intended for production of finished textile articles are cut in this section. Fabrics are transported from the Finishing Plant by carts without initial quality control. Fabrics are inspected on the cutting table while being layered for cutting. Fabrics can be layered in two ways: manually and with a special automatic device on special cutting tables, which are used for fabric with widths from 90 to 300cm. Woven and knitted fabrics for garments are cut with an automatic cutting head which provides a good speed and high cutting quality.
The section of automatic sewing lines
There was built a new sub-section with automatic sewing lines in the Garment Factory in 2007. The section is equipped with the most modern automatic stitching machines. They are:
• 3 lines for production of flat sheets with simultaneous folding of ready items to the preset dimensions;
• 2 lines for pillow cases;
• 1 line for duvet covers;
• 1 line for fitted sheets;
• 1 line for hospital sheets ;
• 1 line for kitchen towels and table-cloths.
Besides this, there are 5 folding lines in this section, which are used for folding such items as fitted sheets, pillow cases and flat medical sheets, as well as garments: gowns, jackets and trousers. There is a vacuum machine used for turning pillow cases and duvet covers inside out.
Automatic folding lines and vacuum machines help to shorten time and reduce production costs. Each automatic sewing line is a complex including almost the whole cycle of production of finished articles. One line simultaneously controls the quality, cuts, stitches and folds.
Depending on the type of product to be produced by this or that line, each line is combined with a folding machine or a vacuum machine and a packing desk. Such technological chains help us to shorten the cycle of production and minimize the waiting time.
In 2018, a new sewing section with a modern industrial design, natural lighting and autonomic system of climate control was built to meet all requirements to working places and guarantee the most comfortable working conditions for seamstresses.
In 2019, two semi-automatic machines for forming and simultaneous sewing of two sides of pillow cases were bought, which halved the cost of performing this operation.
In 2019, the factory purchased a new automatic sewing and folding line for flat sheets which can also fold flat sheets and attach RFID tags (tags in roll) and two labels. The function of attaching electronic RFID tags in roll was designed specially for Tirotex and is an innovative robotized operation that was introduced for the first time ever.
The section of automatic sewing lines includes an embroidering section. There are 2 quilting-and-embroidering automatic machines for continuous quilting and embroidering and 5 automatic machines for placed embroidery in this section. Embroidery and quilting allow widening the product range. Embroideries are made on bed linen, table linen, jersey items and home clothes; logos are embroidered on hospital garments and workwear.