Production
Process
Our production process for high-quality towels
Receiving and properly
storing cotton yarn to be
used as the base material
for our towels
Checking consistency against
standards (including dirt,
foreign matter, flaws, and
abnormalities)
inspection
A similar inspection is
conducted with a different
team of
two people to check the
products from a new
perspective
inspection
A secondary needle
detection is conducted
before setup
after leaving the
warehouse
needle detection
Checking the quality of cotton yarn
Production begins with checking the quality of yarn, the base material of our towels. In this process, the strength of the yarn, the length of fibers, etc. are inspected in our factory laboratory.
Receiving and properly storing cotton yarn to be used as the base material for our towels
Once the quality of the yarn is confirmed, the yarn is carefully stored in our materials warehouse. The storage environment is critical, and the temperature and humidity are kept constant.
Wrapping each yarn that constitutes a towel on the beam
This is preparation stage [1] before weaving begins. A bundle of yarn is wrapped around a large winder called a beam so that it can be put on a loom.
Applying glue to yarn
This is preparation stage [2] before weaving begins. Glue is applied evenly to the yarn before it is placed on the loom. The glue increases the strength of the yarn and prevents it from breaking during the weaving process.
Placing yarn on a loom and weaving fabric
We weave towels. Our company can weave 1000 towels per machine and our entire factory can weave about 160,000 towels per day.
Inspecting woven fabric for any flaws
We inspect the woven fabric for flaws using a fabric inspection machine. If any flaw is discovered, the fabric is examined, marked, and excluded from the following process.
dyeing
Removing impurities and dyeing fabric
The woven fabric is washed to remove any dirt and impurities. Washing the fabric at this stage makes a significant difference in the final product. After this, the fabric is dyed to the desired color.
Drying the fabric in dryers
Dyed towels are put in a dryer. The finish varies depending on the type of dryer used; our company works carefully to make the final products as soft and fluffy as possible.
Preparing the fabric for products that require such preparation
The fabric is stretched and straightened so that it does not become skewed.
Cutting the fabric
The fabric is cut. Cutting the fabric accurately and straight increases its strength without the sides of the towel fraying or breaking.
Placing a pattern on the fabric
Various patterns can be printed on the towels. Prints using up to 16 colors are possible.
Embroidering the fabric
Various embroidery designs can be added to the towels. Embroidery designs using up to 12 colors are possible.
Sewing the hems and edges
Our company is automating our sewing processes. By automating our sewing processes, we can reduce labor costs and facilitate more stable quality in our finished products.
Checking consistency against standards (including dirt, foreign matter, flaws, and abnormalities)
A team of two people inspects the products for dirt, poor quality sewing, flaws, foreign matter, and abnormalities in appearance.
A similar inspection is conducted with a different team of two people to check the products from a new perspective
A new team of two people brings new perspectives and inspects the products for dirt, poor quality sewing, flaws, foreign matter, and abnormalities in appearance.
Stored in primary warehouse after passing through a needle detector
After measuring the weights of products, the products are checked using a needle detector to check for any metal elements before being stored in a warehouse.
A secondary needle detection is conducted before setup after leaving the warehouse
Products taken from the warehouse undergo another needle detection.
Folding, packaging, affixing labels, etc. to complete the products
The products are assembled into the specified form through folding, packaging, etc. This is done while checking against the physical sample, such as whether it matches the specified JAN and whether the labels are appropriate.
Performing the final needle detection
To make absolutely sure, we conduct a third needle detection when the products are completed.
Packing in cartons
We carefully check the contents against the carton description and pack them with care to avoid damage. We also pay attention to the strength of the carton.
Shipping to a port
The products leave for a port before being shipped around the world.
