Textile Production Process — From Cotton to Container
AHK Fashion's vertically integrated manufacturing process covers every stage from raw cotton sourcing to final container loading. ISO 9001:2015 certified at every step.
Our 13-Step Manufacturing Process
Step 1: Raw Cotton Sourcing
Procurement of certified premium cotton from Punjab and Sindh, Pakistan. We source Grade-A cotton with staple length 1-1/8" to 1-3/8" ensuring superior yarn quality.
Cotton Grade: A+, Staple: 1⅛"–1⅜"Step 2: Ginning & Bale Pressing
Mechanical separation of cotton fiber from seeds. Bales are pressed to standard 170–185 kg weight and tested for moisture, micronaire, and fiber strength before dispatch to spinning.
Bale Weight: 170–185 kg, Moisture: <8%Step 3: Yarn Spinning
Ring-spun, open-end (OE), and air-jet spinning lines producing 10s to 120s count yarn. In-process quality checks at every stage ensure evenness, tenacity and elongation values meet buyer specifications.
Count Range: 10s–120s Ne, CVm <12%Step 4: Yarn Dyeing
Reactive, vat, disperse and direct dyeing in hank and package form. Colour fastness to washing (Grade 4-5), rubbing and light tested as per AATCC/ISO standards.
Fastness: 4–5 wash/rub/lightStep 5: Warping & Sizing
Warp yarn is wound onto beams and sized with starch or synthetic sizing agents to improve weaveability and reduce breakage during weaving. Beam weight and tension are computer-controlled.
Sizing Add-on: 8–12%, Auto-tension controlStep 6: Weaving / Knitting
Rapier, air-jet, and projectile looms for woven fabrics. Circular and flat-bed knitting machines (20 to 36 gauge) for knitted constructions. Grey fabric is produced per buyer order specification.
Loom Speed: 600–900 RPM, Width: 44–120"Step 7: Grey Fabric Inspection
100% inspection using 4-point system under standard light (D65). Fabric points are calculated per 100 linear yards. Rolls exceeding AQL 2.5 are quarantined for re-weaving or downgrading.
4-Point System, AQL 2.5Step 8: Washing & Scouring
Enzymatic scouring and bio-washing removes sizing agents, natural waxes and impurities. Hydrogen peroxide bleaching for white and light-shade fabrics. Water is treated before discharge.
H₂O₂ Bleaching, Zero Effluent DischargeStep 9: Fabric Dyeing & Printing
Continuous dyeing (Pad-dry-thermosol), jigger, winch and jet dyeing machines. Rotary screen and digital printing for pattern fabrics. Color matching with Datacolor spectrophotometer.
ΔE <1.0, Datacolor SpectrophotometerStep 10: Finishing
Calendering, Sanforizing (residual shrinkage <1%), softening, water-repellent (DWR), anti-wrinkle, anti-microbial and flame-retardant finishing applied as required. Stenter for width and GSM control.
Shrinkage <1%, Custom finishes availableStep 11: Final Quality Control
AQL 2.5 inspection of finished fabric. GSM, width, color fastness, tensile strength, tear strength tested in-house. Third-party lab testing by SGS, Bureau Veritas or Intertek on request.
AQL 2.5, SGS/BV/Intertek certifiedStep 12: Cutting & Packing
Fabric rolled on cardboard tubes, polybag-wrapped, and labelled with roll number, lot, width, weight, and colour. Packed in export-grade cartons or on pallets as per buyer packing specifications.
Polybag + Export Carton, Custom labelsStep 13: Container Loading
FCL (20' and 40') and LCL export shipments. Container stuffing supervised by our QC team. All documents — packing list, invoice, COO, SGS report, fumigation certificate — provided before departure.
FCL/LCL, Karachi & Port Qasim