Spinning Mill

Gene Apparels started up producing yarn since 2006 in a convertion basis, with a tie up between Gene and yarn spinning mills in south India. The strategy was Gene invested in cotton and the mills produce the yarn as convertion job works. Despite of crisis in the industry due to drastic increase in cotton price globally, the convertion process strategically worked competing price challenges. In 2009 Gene ventured into spinning division with a capacity of 50,400 spindles producing yarn counts from Ne 16s to 40s for Hoisery.

The current production capacity is 38 tons per day with a state of art facility in spinning from blow room carding comber & draw frame from Reiter Switzerland ring frames from LMW India, Linkconer from Murata Japan and Testing equipment's from Uster Switzerland. In just a short span of time we have been able to carve a niche in manufacturing Auto coned SIRO cleared cotton yarns for both normal and organic range of Hosiery applications.

knitting division

Here is the base of a fabric , a division of GENE that knits grey yarn into a fabric through computerised circular knitting machines. We make various structured fabrics and designs like Ribs,Interlocks,Jersey,Fleece, Jacquards,Stripes - Auto / Feeder / Vertical,Jersey Spandex, French terry spandex,Plaited jersey etc....

fabric processing

Our processing plant with highly sophisticated soft flow machines holds a capacity of dyeing & finishing 8000 kgs / day and a Washing unit with a maximum capacity of 4000 pcs per day (enzyme, stone wash, denim wash, silicone, acid wash, crinkle wash, mineral wash, gel wash and bio wash). The quality standard of dyes and liquors used are as according to OEKO TEX 100 requirements..

fabric finishing

Our compacting division co-ordinates in finishing the fabric with a total capacity of 7000 kgs/day, controlling all the quality parameters of the processed fabric stringent to the required standard. Our finishing dept situated next to the fabric processing unit is a major advantage for a chain process. The fabric finishing starts from the padding section (santex) followed by drying as a continues process. All basic and client specified quality parameters will be checked by our fabrication team. In all cases a trial roll will be compactes and monitored. Accordingly the bulk fabric will be given the accurate finishing.

Printing division

Garment printing facility for placement prints spot in pigment, plastisol, flock, foil, hi-density, discharge, sueded, distressed, photo prints and simmer prints. With a capacity of 8000 pcs / day. Our printing premises are highly maintained with use of phthalate free, Azo free, formaldehyde free and lead free dyes. For all over printing our facility runs a 10 color starmac rotary machine. In addition we have latest updated machines opt for burnouts and sublimation prints with improved quality and less rejections. The quality standard of printing dyes and chemicals used are as according to OEKOTEX 100 is approved.

EMbroidery division

Our embroidery division is of computerized embroidery machines (BARUDAN) with a capacity of 40heads and productivity of minimum 920000 stitches per day. Also includes a separate 2 head machine only for sampling. We have a well qualified design team expertised in understanding and giving suggestions for better output.

fit studio & pattern evaluation

Our Fit Studio with ALVA size forms turns out solving fit issues in the very initial stage itself. Every submit from proto, actual fits, PPS the samples has been trailed on the size form of the desired size. Our technicians and pattern makers discuss the critical points with the client by sending digitals, video conferencing or digitizing concern pattern in the CAD and send by PDF format.

cutting & sewing division

The garmenting division is well equipped with all the latest machinery to make contemporary style and to ensure perfect finish of garments which is the outcome of planned work flow and quality control systems. Modernized production unit with imported spreading machines and lay cutting machines, high-tech power sewing machines and finishing machines are the upper hand of our factory. Our factory holds a overall capacity of producing 700,000 units every month considering 50% of basic Tee’s and 50% of high fashion value added styles.

laboratory

Equipments -

• IFB -Washing Machine - 2 nos

• IFB - Dryer

• Laundro Meter(Chemical Test)

• Crocking Machine

• GSM Cutter

• Weight Scale (1000GRMS)

• Warp Reel (Yarn Count Testing Machine)

• INTERNAL FABRIC TEST :

  • Dimensional Stability

  • Appearance after washing

  • Spirality

  • Color fastness to washing

  • Color fastness to crocking

  • GSM

• INTERNAL GARMENT TEST: Bulk size set garments are used for garment physical test

  • Shrinkage (Dimensional Stability)

  • Appearance after washing

  • Spirality

  • Color fastness to washing

  • Color fastness to crocking

  • GSM

• One garment from every 1000 Pcs production is checked as per home laundry

  • Appearance after washing

fabric inspection

• Bulk grey fabrics are inspected by 4 point system

• 100 % Dyed fabrics is inspected and audited by 4 point system

• GSM of every bulk rolls are punched and recorded.