Every voyage has a start and an end. Even with the best laid plans, it is easy to lose direction along the way and end up at a destination that is very different from what was planned. At Alkaram, we ensure that our products never stray far from their goal. From the first step of their iourney. the creation of fibers via spinning, down to the last, of stitching the finished fabric, our products are constantly checked to ensure they end up exactly how our customers want them. Each step is carefully planned. We have a fully integrated services facility that uses the latest technology across all parts of the products' voyage. For this reason, Alkaram products never lose their way.
The raw cotton arrives in the form of large bales. From here, the cotton goes to a machine which cleans the cotton of any remaining dirt and separates the ﬁbers. The cotton emerges in the form of a thin blanket. The fibers are separated more completely. The output from these machines is more like an untwisted rope than a blanket. This is carried out on a madiine called a 'draw frame'. This further straightens the ﬁbers. The yarn is further attenuated - i.e., it is stretched so that the weight per unit length decreases further. The term 'spinning' is used to denote the process in the production of the yarn. The thread is strengthened by adding a twist to it and then wound onto a bobbin. Cleansing is required to remove the trash such as dirt, leaves, burrs and any remaining seeds. 'Carding' is the initial straightening process which puts the ﬁber into a parallel lengthwise alignment. This process untangles the tangled mass and molds it into a round, rope-like form called 'sliver'. The sliver is then straightened again through a process called 'combing'. In it, fine-toothed combs continue straightening the fibers until they are arranged in such a parallel manner that the short fibers are completely separated from the longer ones. 'Drawing' pulls the staple lengthwise over each other. As a result, longer and thinner slivers are produced. After several stages of drawing-out, the sliver is passed to the spindles where it is given its ﬁrst twist and then wound on bobbins. 'Roving' is the final product of the several drawing-out operations. It is the preparatory stage for the final insertion of twist. Till now, the ﬁbers are given enough twist to hold them together but they have no intense strength. They can break apart easily with a slight pull. The 'roving', on bobbins, is placed in the spinning frame, where it passes through several sets of rollers running at high speeds and ﬁnally the 'yam' is produced of the sizes desired.
'Weaving', the second step of the vertical textile chain, is the art of interlacing yarn to make a piece of cloth/fabric. It involves taking two sets of formed yarn and interlacing them at right angle. The lengthwise yarn is known as warp threads and the crosswise or ﬁller yarn, weft threads. Before the 'weaving' is done, there are a few preparatory processes involving 'warping' (it is the process of creating the base yarn that runs from top to bottom on woven cloth), sizing (the addition of starch to give strength to the yarn to avoid breakage) and then weaving.
Our Weaving Capabilities
- - Complete Fabrication solution provider with largest shed of Wider Width High Thread Counts, dobbies, Yarn Dyed, jacquards & over 400 looms.
- - Simultaneous and multiple weft insertion capability; 4 color welt insertions and dobbies.
- - Largest capacity to weave Yarn Dyed fabric in Pakistan.
Yarn Dyeing is a process of adding color to textile products like fiber and yarn. It is normally done in a special solution containing dyes and particular chemical material. After dyeing, dye molecules have an uncut chemical bond with the fiber molecules. The temperature and time control are two key factors in dyeing. There are mainly two classes of dye, natural and man-made. There are many forms of Yarn Dyeing, from which the package form is most commonly used. The common dyeing process of cotton yarn with reactive dyes in the package form involves the raw yarn being wound onto a spring tube to achieve a package suitable for dye penetration. These softened packages are loaded onto a dyeing carrier's spindle, one on top of another. The packages are pressed up to a desired height to achieve suitable density of packing. The carrier is loaded on the dyeing machine and the yarn is dyed. After dyeing, the packages are unloaded from the carrier into a trolley. Now the trolley is taken to hydro-extractor where water is removed from them. The packages are hydro-extracted to remove the maximum amount of water, thus leaving the desired color into the raw yarn. They are then dried to achieve the final dyed package.
Our Yarn Dyeing Capabilities
- - Capacity of 18 tons per day.
- - All machines are air-packed.
- - One-time dyeing capacity ranges from 2 lbs - 4000 lbs
If required, the created fabric is reduced in size by steeping it in diluted acid and then rinsing it. Enzymes may also be used. 'This is known as 'de-sizing'. If the Fabric in question is cotton, then it is chemically washed to remove impurities such as natural wax, non-fibrous impurities and any dirt that may time been accumulated over the previous process. If reagents are incorporated correctly into the process, the fabric becomes smaller in size. At the end of this 'scouring'process, most cotton turns out to be yellowish, and then requires bleaching to make it white. For cotton which will he dyed deeper shades later on, lower levels of bleach are used. The strength, dye affinity and luster result from 'mercerizing' the fabric which involves treating it with caustic soda to cause the fibers to swell.
The fabric then needs to be made smoother. By passing it over brushes, the ﬁbers of the cloth are raised. These fibers are then singed of by passing it over a heated plate. Depending on the fabric type, the 'raising' process is applied, where the fabric surface is treated with sharp teeth, imparting hairiness, softness and warmth. The fabric can then be 'calendared' by passing it between heated rollers to increase the smoothness and polish it. It is then mechanically shrunk to prevent shrinking after our consumers purchase it.
Finally, the fabric can by dyed by submerging it into a dye solution for a period of time. Alternatively, or after dyeing, we then print our imagination onto the fabric. Textile printing is the process of applying color to fabric in deﬁnite patterns or designs. In properly printed fabrics, the color is bonded with the fiber, so as to resist washing and friction. Textile printing is similar to dyeing in which the whole fabric is uniformly covered with one color. In printing, however, one or more colors are applied to certain pans only and in sharply defined patterns.
In printing, engraved plates, rollers or silk screens are used to place colors on the fabric. Colorants contain dyes thickened to prevent the color from spreading beyond the limits ol the pattern or design by capillary attraction.
Our Wet-Processing Capabilities
- - Vats, reactives, pigments, Disperse/ Reactive, Disperse/Vat and woven & knitted fabrics printing and dyeing.
- - Huge capacity of Flannel Production.
- - Largest producer of Yarn Dyed fabric in Pakistan.
- - Specialized ﬁnishing capability according to our customers' requirements.
- - Flannels and brushed twills printing and dyeing. Once the cloth is ready in its final form, it is cut and stitched by advanced automatic cutting and sewing machines.
Cutting & Stitching
The finished fabric will now be changed into products. It goes through the process of cutting and stitching, where one of numerous techniques may be applied depending on which type of product is required. Our capabilities and capacities include: latest folding machines range with wrapping facility; 125,000 meters CMT; production of 15,000 woven sheet sets and quilt covers per day; production of 10,000 jersey sheet sets per day; more than 900 stitching machines with the capacity of producing various kinds of stitching items and different hem treatments; 1,200 per day Bed in a Bag, plus Room in a Bag with complete filling solutions; up to 1 million Fabric Warehousing Facility in finished form; up to 1.5 million Fabric Warehousing Facility in Greige form. The facility has the capability of various stitching techniques at the highest production level and of producing all kinds of Applique; made-ups of all types i.e., bed linen, quilt covers, sheet sets and pillow cases; garments for men and women's night wear and fashion wear; curtains and kitchen linen. Alkaram Textile, in collaboration with the Ministry of Textiles, the Government of Pakistan has embarked on a training project for the development of a skilled work force. For this purpose, we have designed an in-house systematic training system for a cutting & stitching skilled labor force.
Retail & Distribution
Once our creations of imagination are ready to wrap themselves around our stylish customers or decorate their welcoming homes, they are taken to one of our various distribution centers. By creating a retail network where each shop is specialized to suit a certain type of customer, Alkaram focuses on satisfying each customer via ease of access and the widest ranges.
- ~ Alkaram fabric is distributed throughout Pakistan via a distribution network of independent retail outlets and fabric stores.
- ~ Alkaram Studio is a retail chain that specializes in providing classy attire for men and women, from local to international styles of clothing.
Distribution- A vast network of dealers, whole sellers, and retailers, our products reach more than 200 outlets nationwide.