Our Fabric Production
Process

At Hayleys Fabric Plc, our fabric production process is a carefully orchestrated journey that begins with sourcing top-quality raw materials and culminates in the delivery of exquisite fabrics that meet our customers’ highest expectations. Our commitment to excellence is rooted in every step we take, ensuring that each fabric we create is a testament to our unwavering dedication to quality, innovation, and sustainability. From meticulous raw material selection to state-of-the-art dyeing, printing, and finishing, our process is designed to deliver fabrics that set industry standards while fulfilling the diverse needs of our global clientele.

Explore each facet of our fabric creation process, highlighting the precision and technology we employ at every stage to produce fabrics that delight our customers worldwide.

Raw Material

We source high-quality raw materials from suppliers certified for their exceptional social and environmental management practices, with stringent focus on global compliance standards and the right quality of raw materials in responding to our customer demands.

Yarn, the main raw material is sourced from the region, while dyes and chemicals are sourced both regionally and from Europe. All raw materials undergo thorough inspection to ensure that they meet the stipulated compliance standards and quality standards that underpin the excellence of our fabrics.

Colour Laboratory

Our cutting-edge colour laboratory is equipped with the latest Datacolour – colour management system, which is used to formulate dye recipes.

Spectra readings are captured for all lab-dips to ensure that DELTA values are maintained below the specified limits.

Lab-dips are continually evaluated to ensure highest quality is met with lowest cost.

Knitting

Knitting is the transformation of thread or yarn into semi-finished fabric, known as “greige.”

Weft-knit fabric is crafted using our state-of-the-art Orizio, Santec, Fukushara, and Mayer knitting machines that are capable of Single Jersey, Double Jersey (also known as Interlock) and Rib fabrics. We also possess a comprehensive Flat Knit knitting section which is used to produce bands and collars.

Our mill is capable of producing a variety of designs or structures on weft-knit fabrics, such as Pique, Waffle, Slub yarn designs, Metallic yarn designs, Inlay (loopback).

All greige is checked on-line for defects while being manufactured in our Knitting department, and again re-inspected by our quality assurance department to ensure that only fabrics of the right quality are passed on to the next process.

Dyeing

Dyeing adds colour to the knitted fabric to give it a rich and exuberant appeal. We have the capability of dyeing both pure and blended cottons and polyester fabric using the Sclavos, Thiese, and Fongs dyeing machines equipped in our dye-house.

Our dye-house operations are controlled using Sedo and OrgaTEX systems, while the colour of the fabric is achieved and repeated by an automated chemical dispensing system.

Printing

Textile printing is the process of applying colour to fabric in sharply definite patterns and designs.

Our CAD division in the printing department is equipped with the latest CAD/CAM software from AVA, and our screen engraving and screen preparation divisions use laser engraving technology to engrave print screens for accuracy and consistency.

Our eight-colour Rotary screen printing machines are capable of producing full coverage prints, vertical stripes, prints with tight registration or intricate designs on cotton, cotton-blends, polyester, polyester-blends and viscose fabrics, including pigment printing.

Brushing

Brushing, Raising or Napping gives the fabric a soft, slightly weathered, broken-in feel.

Fabric is brushed using a fuzzy surface by abrading the cloth and pulling the fibre ends to the surface.

Sueding

Sueding gives the fabric a soft, smooth and sensational feeling and it also modifies the appearance of the fabric. Fabric can be sueded on one side or on both sides.

Shearing

Shearing is a dry, permanent finish used to create a uniform surface on napped or pile fabrics.

This fabric cutting operation determines the height of the fibre and cuts off any fibres that are irregularly raised during the raising process.

Sheared fabric has the appearance of velvet fabric and has a soft feel to the hand.

Combing

Combing removes the fuzz and gives a smooth appearance to the fabric.

Finishing

Finishing is the process that transforms fabric into its usable form by enhancing its look, performance and ‘hand’ feel. It is the final step in our manufacturing process and ensures that the final look and feel of the product aligns with our customers’ specifications.

Our world-class finishing machinery from Babcock, Santex, Sperotto Rimar and Tong Yang, incorporate in-built automatic controls to guarantee precise physical measurements in every fabric we produce. All our fabrics are also inspected on-line at this stage to ensure that these physical parameters are achieved.

Our finishing capabilities also include moisture management, water repellent, UV protection, aguacate and anti-microbial.

Only the fabrics of the right quality are passed onto the next division – Quality Assurance.

Final Inspection / Quality Control

We consistently uphold and deliver exceptional quality standards across the company to delight our customers around the world.

All fabrics undergo a rigorous 100% final inspection for any visual defects, colour inconsistencies or inaccuracies, and the desired physical properties to ensure that only the right quality fabrics reach our customers.

Our Quality Policy is communicated and understood at all levels within the organisation.

Process Control

We employ the SAP-ERP system to seamlessly integrate our business functions including Sales & Marketing, Procurement, Warehousing, Production, Finance and Controlling.

FastReact, a specialised tool tailored for the textile and fashion industry, is used for production planning. This enables us to achieve enhanced operational efficiency through streamlined coordination between Sales & Marketing, Procurement, and Production.

Our Fabric Production Process