Through state of art technology, we are able to reduce wastage at every process, thereby reducing manufacturing cost and increasing efficiency. Keeping abreast of the latest technology has made us serve our customers more effectively. When advanced technology and state of art equipment are in the hands of experienced professionals, no task is difficult or challenging.
We understand that to make fine quality fabrics, we need to source best quality wool. Clean or scoured wool is delivered to our mill by reliable suppliers from around the world. Before the wool is delivered to our compound scouring is done to remove impurities such as dirt, grease and suint.
Lubricant and water is mixed together and applied to the scoured wool. This process is done to remove remaining contaminants such as grass, dust and dirt. After carding, the fibres are more parallel to each other,allowing adequate blending of the wool.
After being carded, the wool fibres are spun into yarn. Spinning is the most important and the initial step in fabric manufacturing. Yarn is made by twisting and thinning the wool strands to make a fine yet strong yarn out of wool fibres. The faults are cut out of the thread and the ends thermally joined together leaving a yarn that will weave into smooth fabrics. Currently our monthly spinning capacity is 50 Tonnes.
Warping is parallel winding of yarn from cones on to a warp beam. This is done to arrange a convenient number of warp yarns of related length that can be collected on a single warp beam. It is a process for making the weavers beam.
Weaving is the process of making cloth with two components, a warp and a weft. Our mill uses automatic rapier looms to meet the export standards. Once the fabric is woven, Our inspection team thoroughly goes through the fabric to identify and rectify weaving faults. Currently, Our monthly weaving capacity is 100,000 Meters.
Immediately after weaving, every inch of newly woven cloth is inspected for any flaws or imperfections. Our skilled darners remove any faults by hand and, if necessary, intricately re-weave portions of the cloth prior to final finish.
The Greige fabric after passing the quality standards is sent to our other unit- Himalaya Processors Pvt. Ltd. Here the fabric is processed and finished to a perfect, flawless condition. Our monthly capacity is 500,000 Meters.
There are various finishing procedures for the woollen fabrics;
In this, a strong acid is used to remove Vegetable matter, skin flakes and other impurities from the fabric.
The fabric is washed before it can be milled, this is done to neutralise the fabric. This process produces a wide range of effects, the most important being controlled fabric shrinkage and partial concealment of the woven structure.
Best quality dyes are procured for our fabrics with the goal of achieving colour with desired colour fastness.
A drying process to coordinate the measurements.
A finishing process that raises the fibres on a fabric.
Cutting of the raised fibre to provide uniformity and appearance. We guarantee to pass all the pilling standards.
Every length of fabric is carefully pressed using steam.
We use energy efficient machines which are suitable to correct any weft distortion by using an optical system.
To give stabilisation as well as a smooth surface to the fabric.
The fabric is then handed over to our Quality control team to ensure that the requisite quality of fabric is achieved.
After the approval by the quality team, Benu Textile’s brand seal is ironed on to the fabric as the ultimate mark of authenticity.
Fabrics can now be sent off to its proud new owner, who might be nearby, or on a distant continent half way across the world. Wherever its destination, the fabric will be enjoyed and appreciated by all.