How do we manufacture Polo & Round Neck T-Shirts at TeeOne

The manufacturing process for cotton t-shirts involves several intricate stages that transform raw cotton fibers into the finished garment. Here's an overview of the typical steps involved:

1. Cotton Cultivation: The process begins in the fields where cotton is grown. Indian cotton, known for its quality, undergoes cultivation, requiring careful attention to soil quality, weather conditions, and pest management. Once the cotton bolls mature, they are harvested.

2. Ginning: After harvesting, the cotton fibers need to be separated from the seeds and other impurities. This is done through a process called ginning. The cotton is fed through machines that remove seeds, dirt, and other debris, leaving behind raw cotton fibers.

3. Spinning: The ginned cotton fibers are then spun into yarn. This process involves twisting and drawing out the fibers to create strong and continuous threads. Different spinning methods result in various yarn types, like combed yarn or carded yarn, each with its specific qualities.

4. Knitting or Weaving: The yarn is then used to create the fabric. For t-shirts, the fabric is either knitted or woven. Knitting creates a stretchier fabric commonly used for t-shirts. Circular knitting machines produce tubular fabric, while flat knitting machines create fabric in sheets.

5. Dyeing and Bleaching: The fabric is often dyed to achieve the desired color or pattern. This can involve various techniques and dyes, depending on the design requirements. Some fabrics might also undergo bleaching to achieve a lighter base color before dyeing.

6. Cutting: Once the fabric is ready, patterns for t-shirts are laid out, and cutting machines precisely cut the fabric into individual pieces according to these patterns. This step ensures uniformity in size and shape.

7. Sewing: The cut pieces are then assembled and stitched together by sewing machines. This process includes attaching sleeves, adding collars, and finishing the edges. Skilled workers ensure that the stitching is accurate and durable.

8. Trimming and Inspection: After sewing, excess threads are trimmed, and the t-shirts undergo thorough inspection for any defects or irregularities in stitching, fabric quality, or dyeing.

9. Finishing: T-shirts might undergo processes like softening or treatments to enhance their feel and appearance. Labels, tags, and other branding elements are added during this stage.

10. Quality Control and Packaging: Final quality checks are performed to ensure that the t-shirts meet the required standards. Once approved, the shirts are folded, packed, and prepared for distribution and sale.

Throughout this entire process, quality control measures are implemented at each stage to ensure that the cotton t-shirts meet industry standards in terms of durability, colorfastness, comfort, and overall quality. The process combines traditional craftsmanship with modern technology to produce the comfortable and stylish cotton t-shirts that consumers love.