Manufacturing
Our process of product creation
Always striving for the best quality.
From Japan, China, and Vietnam,
we create towels
that are the pride of the world.
Always striving for the best quality.
From Japan, China, and Vietnam,
we create towels
that can be the pride of the world.
Our products have direct contact with delicate skin.
Our aim is to produce the ideal towel.
We have been involved in towels for more than half a century since our foundation. By leveraging the strategic planning and development expertise of a Japanese company, A-Z Corporation, along with state-of-the-art production facilities in China and Vietnam, we ensure the creation of high-quality towels while meticulously managing delivery schedules.
We conduct comprehensive annual inspections on cotton sourced globally, evaluating it against 10 different parameters. Only cotton that successfully passes these rigorous assessments is procured. Our manufacturing process takes place in two cutting-edge factories where integrated systems cover every stage from thread twisting and fabric weaving, dyeing, sewing, delivery and post-purchase support.
In addition to conducting quality control checks after each production process, our commitment to excellence is reinforced through the implementation of automated systems, significant capital investments, optimal staffing levels, and streamlined business operations. These measures collectively guarantee both high-quality products and prompt delivery, all while prioritizing the safety and well-being of our staff in the workplace.
Indulge in a soft texture that beckons for repeated use and melds with your skin while being enjoyed. Not only does its comfort endure but it also grows softer over time, ensuring prolonged luxury. From opulent towels crafted by luxury brands to everyday essentials, we cater to diverse customer needs, consistently surpassing expectations with our superior products.
We produce world-class towels in our two production facilities located in China and Vietnam.
Nantong Dadong Co., Ltd. is located in Nantong City surrounded by beautiful views of the Yangtze River and the Yellow Sea. Since its establishment in 1987, it has received technical guidance from Japanese towel manufacturers to create the most advanced production environment in China. This plant mainly produces luxury brand products, such as A-Z Corporation’s original brand, SODATERU TOWEL®.
Vietnam Dadong Co., Ltd., which was established in 2016 on a large 93,000 m² site, introduced looms made in Switzerland, Italy and Japan, and established a system that manufactures approximately 80 million towels per year. It produces a variety of towels to meet the needs of customers, from luxury brands to general purpose towels.
We oversee more than 20 processes and conduct meticulous inspections.
From material inspection to final shipment, the production of our towels entails a multitude of meticulous processes. We’ve made significant capital investments to deploy cutting-edge automated systems, not only to mitigate human error but also to ensure rigorous process control. At every stage, materials undergo thorough inspections to maintain quality standards. Even upon completion, we conduct comprehensive checks for frayed threads, cleanliness, pH values, etc., approaching each inspection from multiple perspectives. Furthermore, our needle inspection process includes a total of three examinations, leaving no room for oversight.
We uphold the standard of excellence by integrating state-of-the-art automation equipment and implementing a rigorous inspection system. This dedication ensures the delivery of safe, secure, and high-quality products to our customers.
PROCESS
-
01 Yarn inspection
Checking the quality of cotton yarn
-
-
02 Delivery of yarn
Receiving and properly storing cotton yarn to be used as the base material for our towels
-
03 Yarn wrapping
Wrapping each yarn that constitutes a towel on the beam
-
04 Sizing
Applying glue to yarn
-
05 Weaving
Placing yarn on a loom and weaving fabric
-
-
06 Inspection
Inspecting woven fabric for any flaws
-
-
07 Refining bleaching/dyeing
Removing impurities and dyeing fabric
-
08 Drying
Drying the fabric in dryers
-
09 Tentering
Preparing the fabric for products that require such preparation
-
10 Slitting
Cutting the fabric
-
-
11 Printing
Placing a pattern on the fabric
-
12 Embroidery
Embroidering the fabric
-
13 Sewing
Sewing the hems and edges
-
-
14 Primary inspection
Checking consistency against standards (including dirt, foreign matter, flaws, and abnormalities)
-
15 Secondary inspection
A similar inspection is conducted with a different team of two people to check the products from a new perspective
-
-
16 Primary needle detection
Stored in primary warehouse after passing through a needle detector
-
17 Secondary needle detection
A secondary needle detection is conducted before setup after leaving the warehouse
-
-
18 Setup
Folding, packaging, affixing labels, etc. to complete the products
-
-
19 Tertiary needle detection
Performing the final needle detection
-
20 Packaging
Packing in cartons
-
21 Shipment
Shipping to a port
