Methods & Process

Ginning
Carefully grown raw cotton is chosen from cotton growers around Coimbatore although ginning is not a part of VTX activity.
Cotton is also outsourced / imported to fulfill buyers requirements. Examples of these types of cotton are Supima, Egyptian Cotton and Russian.   

Spinning
The Spinning unit has 46,000 spindles, which is capable of producing 3.5 tonnes of combed yarn per day. Our spinning unit caters most of the Super fine count yarn requirements of our Weaving unit, like 2/110s, 90s(II), 2/120 Gassed, 90s(II) Gossamer, 2/120s GMY, 2/60s GMY, 2/140s Gassed, 4/170s Gassed and 2/80s Gassed. Yarn is also Exported and supplied locally as below:
 Local: 100/2HT Gassed, 100/1 DHCR, 100/1 Singles combed.
 Export: 94/2, 86/2, 132/2, 160/2 & 160/4 ply as Grey. 120/2 & 140/2 as Gassed.
These are exported to Italy and Spain for Albini, Martinelli, Monti, Productos and many yarn buyers.

Weaving
Yarn such as 2/110s, 90s(II), 2/120 Gassed, 90s(II) Gossamer, 2/120s GMY, 2/60s GMY, 2/140s Gassed, 4/170s Gassed and 2/80s Gassed, supplied frorn VTX Spinning  is utilised for fulfilling the product needs of Buyers across the world. The Weaving also out sources 40s, 80s, 60s, Silk Yarn, 44 lea flax, 20s and 30s Carded and 30s combed for the requirement of the buyers.
Winding: The yarn which are brought from different sources are wound into the ring cops to convert to required sizes of cones.

Warping
The cones will then be converted into beams as per the dimensions and the thread count of the fabric needed.
Sectional warping:  the doubled yarns and the dyed yarns are converted to beams for weaving and sizing depending on the need.

Sizing
The yarn is strengthened in this process by applying sizing ingredients with the help of the sizing machines.
This improves the weavability of the warp and to overcome inherent deficiencies of the yarn to with stand the stress and the strains of weaving.  
Finally the weavers beam is wound for final weaving. Sophisticated indegeneous machines are used for this process.

Weaving
The beams are then fixed to the weaving machines where the interlacing of the warp and weft takes place.
The company has about 75 looms, which are shuttle looms, Dobby looms, AirJet, Rapier and Jacquards.
The unit produces around 7000 meters of quality fabric every day. 

Processing
Chemical process consists of series of procii for converting a grey fabric into saleable product. The purpose of bleaching includes removal of various natural and added impurities from grey fabric as efficiently a possible with minimum or no damage to the fibre and leaving the fabric in a perfectly white state. Singeing and desizing forms preliminary process to which grey fabric is subjected before it is scoured and bleached.
The grey Fabric is received in the Grey go down at the processing unit.

Batch Preparation
The fabric thus received is sent for singeing is prepared by stitching together by means of sewing machine after marking at the ends of the pieces for subsequent identification and record. Batches of grey fabric 2000 to 4000 meters are prepared and sent to the respective machines as per the order, capacity and quantity.

Singeing
The process of singeing is carried out with an objective of removing the loose hairy fibres protruding from the surface of the fabric by running the fabric over a gas flame there by giving it a smooth, even and clean appearance. The process also confers better anti pilling characteristics to the fabric.

Desizing
Desizing is the process of removing sizing ingredients both soluble and insoluble applied during sizing to facilitate subsequent process of bleaching, dyeing and finishing, an outstanding feature of enzyme desizing is the specific nature of enzyme action. Diastace hydrolyses only starch without effecting cellulose. The solubilised starch is thereafter removed by hot washing.

Scouring
The main purpose of scouring cotton fabric is to remove natural as well as added impurities of hydrophobic character as completely as possible by subjecting the fabric to the treatment with 3 – 4 % caustic soda solution in presence of wetting and emulsifying agents at boil, followed  by hot washings. After scouring the fabric absorbency is significally improved which is essential during bleaching process.

Bleaching
The removal of cotton wax, natural fats and added fatty matter from the sized and other impurities from the desized fabric during the scouring process leaves the fabric in a more absorbant condition than the grey fabric, but the natural colouring matter present in the cotton is not removed.
The bleaching process is essential for obtaining good whiteness depending upon whether the fabric is dyed or finished pure white. The process of bleaching is carried out by using hydrogen peroxide sloution solution in presence of organic stabiliser at 80˚ - 85˚ C for 1- 2 hours.
By carrying out the above process in jiggerwe produce a fabric with uniform absorbancy and permanent whiteness is produced, this is essential for level dyeing. The effluents generated from all the processes are colourless and are collected in the equiliser of the ETP.

Dyeing
Fabric after bleaching is dyed with reactive colours in different shades depending upon the order assortment. Dyeing process consists of application of dyestuff solution in hydraulic jiggers by exhaustion method. This is followed by fixation and removal of surface colour by mild alkali and soap.
In the dyeing process there are a number of drains which are coloured. The final rinsing drain is colourless. All the streams are collected in the equilising tank before treatment in the ETP.

Drying & Finishing
This is an essential processof drying bleached / dyedfabric to the required width in hot air stenter followed by finishing to impart soft feel in the fabric. During finishing, fabric is passed through a solution of softner followed by squeezing on the padder and drying on the pin frame of the stenter to the desired width. The fabric is stretched and brought to the final look by removal of the creases in the Stenter machines.

Calendering
Calendering  is a mechanicalm process of passing fabric between a series of hard and soft rollers to improve the aesthetics. The final softness sheen and the sheen is acheived by calendering.
The purpose of calendering is to:
Upgrade the fabric hand & impart smooth & silky touch to the fabric.
Compress the fabric and reduce its thickness.
Improve the opacity of the fabric.
Reduce the air permeability of the fabric by changing its porosity.
Impart different degree of lustre to the fabric.
Reduce the yarn slippage.
The fabric is sent for Final inspection &packed for despatch to the made ups unit.

Made up manufacturing: 

The fabric is received in the Fabric stores and preserved for distribution as per the cutting orders to the cutting section. The fabric cut in various dimensions are barcoded and sent to tailoring lines for sewing embroidery and quilting. High end tailoring machines with necessary folder arrangements help in quick sewing of the cut fabric to made ups.
Inspections are carried out in every stage of the sewing process to ensure quality finish. The made ups are sent to the packing section for final inspection and packing.

Starting from the selection of good quality cotton to the manufacturing of the final made up the product undergoes various measures which prove its quality. Products from Vijayeswari Textiles are handled by technically well qualified personnel, this enhances the ovrall look and the quality of the products.

The design team which is headed by the Joint Managing Director creates designs to cater the needs of the design markets. Product development Sections also operate in Processing, Weaving and Made up manufacturing units in co-ordination with the Product Development Department.