One integrated plant

Production process

From yarn to shirt

From the first thread to the finished shirt.

Every stage happens in our own plant in El Obour and is recorded on our system. That lets us move fast, adapt when a customer needs it, and control quality at each step.

Ten stages run in sequence under one roof: the yarn is wound and dyed, laid onto the warp, woven, inspected twice, stored, and finally cut and sewn into shirts. Every stage is recorded on our system.

01Yarn preparation

Winding

Raw cotton yarn is wound onto soft dye packages at an even density, so the colour penetrates every layer evenly in the dyehouse.

02The dyehouse

Yarn dyeing

Packages are loaded onto carriers and dyed to the exact shade in our own dyehouse. Dyeing the yarn before weaving gives stripes and checks their depth and clarity.

03Weaving preparation

Sectional warping

Hundreds of coloured cones feed the creel. The ends are laid in sections onto the warp beam in the exact colour order of the design.

04Weaving preparation

Sizing

The warp sheet passes through the sizing machine, which coats every thread so it stays strong and smooth through thousands of picks on the loom.

05Weaving preparation

Drawing-in

Each warp end is drawn by hand through its heddle and reed dent, following the weave plan of the fabric.

Drawing warp ends through the heddles by hand

06The weaving hall

Weaving

Our weaving hall runs around the clock, turning the warp into fine shirting, from poplin and oxford to dobby and seersucker.

07Inspection

Grey-fabric inspection

Every roll is inspected on a lit inspection machine as it comes off the loom. Faults are marked on the fabric and logged on our system, then corrected before finishing.

Grey fabric over the lit table of the inspection machine

08Inspection

Finished-fabric inspection

After finishing, each roll is checked again for shade, width, hand-feel and defects against the customer's standard, and the results are recorded on the system.

Finished-fabric inspection, logged on our system

09The stores

Warehousing

Yarn, fabric and trims are stored and tracked by lot, so every order starts with the right material.

Illustration of dyed yarn and shirting fabric in the store

10The shirt factory

Shirt making

Cutting, collars and cuffs, assembly, buttons, pressing and packing, each in its own section.

Shirt making

A dedicated section for every stage of the shirt.

Our shirt factory works in dedicated sections, so every shirt passes through specialised hands at each step.

Cutting

Fabric is spread and cut by automatic cutters for precise, repeatable parts.

Preparation

Cut parts are matched, bundled and checked before they reach the lines.

Sewing

Collars, cuffs, plackets and assembly, each on its own specialised line.

Finishing & packing

Buttons, pressing, final inspection and packing to each brand's standard.

Dyed yarn packages, matched to the approved shade

Checking finished shirts in the shirt factory

Quality

Quality is built in at every step, not checked at the end.

Shade control Every dye lot is matched to the approved standard before weaving.
Two fabric inspections Grey fabric off the loom, and finished fabric after finishing.
Final garment audit Every order is checked against the brand's measurements and specifications.
A system at every stage Every stage is recorded on our system, so each lot and each order can be followed from the yarn to the packed shirt.

Our system

One system, from yarn to shirt.

We run every stage of our plant on WMG CRM, our own factory-management and quality-monitoring system, built by our in-house development team. Every item is followed from the contract to the shipment, with the time spent at each stage.

Every item, every stage From the contract and planning through dyeing, warping, weaving and inspection to the shirt and the shipment.
Inspection on every roll Faults from both fabric inspections are logged against each roll and traced to their source: weaving, yarn, preparation or dyeing.
Garment audits Finished shirts are audited against each brand's measurement specifications before they ship.
Day-by-day dashboards Managers follow production, quality and machine stoppages on dashboards, day by day.