Production Process
- Manufacturing
From Raw Fiber to Responsible Towel
At Paul Textiles, our manufacturing process reflects our commitment to quality and craftsmanship. Leveraging advanced European machinery, renowned for energy and water efficiency, we ensure every towel is meticulously made, keeping durability, comfort, and sustainability in mind.
Yarn Sourcing & Sizing
We source high-quality yarn from internationally certified, ethical spinning mills to ensure consistent fiber strength and durability. Our yarn selection includes options such as open-end, carded (ring spun), combed, compact and zero twist varieties. For added strength, reduced friction and smooth weaving, the yarn is sized on automated machines. After sizing, the yarn is wound onto beams, ready for the weaving stage.
Weaving
Our advanced rapier looms (Silver Dyna Terry) and Toyota air jet looms produce both dobby and jacquard pattern terry fabrics, allowing for long runs and custom designs. We have the flexibility of running short runs on rapier looms, and long runs on air jet looms, with size efficiency on wider width looms. Our looms enable us to make consistent quality terry fabric. Each terry fabric roll is checked for its quality according to customer’s parameters and specifications.
Processing
Our process integrates dyeing, bleaching, finishing, and drying to deliver superior fabric quality. Using advanced rope dyeing machines and certified dyes, we achieve vibrant, long-lasting colors through reactive and VAT processes, ensuring precision with automated dosing systems. Specialized finishes, such as anti-odor, softness enhancements, perfumed, wicking, antimicrobial, and flame-retardant treatments, enhance fabric performance to meet diverse customer needs. The drying stage employs tumble and conveyor belt dryers to create a soft, plush texture while maintaining controlled shrinkage, ensuring each towel exceeds expectations for quality and functionality.
Stitching
We utilize cutting-edge machinery for precise stitching, offering options like single and double-needle lockstitch and chain stitch hemming. Our advanced auto long hemming machines feature automatic sensors that detect hem selvage width to ensure precise selvage stitching. Additionally, we employ Japanese Juki auto trimmer machines to reinforce corners, enhancing durability and strength.
Packing & Warehousing
Each towel is inspected and packed to customer specifications, with packaging options like corrugated cartons or bales. Packages are labeled and prepped for secure shipment. Finished products are stored in optimal conditions to maintain quality until delivery.
Quality Assurance and Compliance
Rigorous audits and strict SOPs, backed by Enterprise Resource Planning (ERP) systems, ensure traceability and compliance at every step. Collaborating with renowned labs for fabric and color fastness and checking all parameters to ensure top-quality standards in every towel.
