- LEED Platinum-certified facility
- Offices in the UK, Spain & Germany
Our process
Controlled from cut to finish.
From digital pattern making to final packing, every stage of denim production is managed under one roof, giving our partners greater visibility, consistent quality and reliable production throughout the manufacturing process.
pieces produced per day
integrated departments under one roof
days average lead time
01–06
The journey
Every garment has a journey.
Our purpose-built facility produces over 40,000 pieces per day, with every stage of denim manufacturing carefully managed and quality checked under one roof.
01
CLO 3D fit approvals and Gerber pattern making feed automated cutting, with every panel inspected.
02
Embroidery and detailing are handled in-house on cut panels, keeping timelines and quality under one roof.
03
Skilled operators work alongside automated VI.BE.MAC units and auto pocket setters for pockets, belt loops, fly pieces, side seams and hems.
04
Hand sanding, grinding and destroy techniques build authentic wear into every garment before it is washed.
05
Wet process
Yilmak and Brongo front loaders, Jeanologia nano-bubble technology and ozone washing.
06
Laser and ozone finishing, final inspection and packing, ready to ship in 60–90 days on average.
00
Digital development
1 week saved on fit approvals with digitized CLO 3D submissions instead of physical sample rounds
Engineered digitally,
approved a week sooner.
Every style starts in our digital pattern room. Virtual samples built in CLO 3D let us submit fits digitally for approval, replacing physical sample rounds and saving around a week of development time. Patterns are then engineered in Gerber Technology software, so the same precise data carries straight through to cutting.
CLO 3D virtual sampling
Digitized fit submissions let buyers review drape, fit and detail on screen before a single panel is cut.
Gerber (GGT) pattern making
All pattern making and marker planning run on Gerber Technology software for accurate, repeatable cutting.
Digital to cutting room
Approved patterns and markers move directly into production, with no re-drafting between sampling and bulk.
01
Cutting
Precision starts with the first cut.
Our Cutting Department uses advanced Bullmer spreading and cutting technology, supported by skilled operators trained in denim specific techniques. Gerber planned markers keep every lay accurate and consistent, with less fabric waste.
Quality and precision before production.
Every panel is verified before production to ensure consistent quality, accuracy and reduced material waste throughout the denim manufacturing process.
01
Fabric inspection
Quality cotton fabrics, sourced from trusted local and regional mills, are inspected before spreading.
02
Pattern marking
Gerber markers plan accurate, consistent lays that make the most of every roll.
03
Automated cutting
Bullmer technology cuts accurate, consistent fabric panels using denim specific techniques.
04
100% panel inspection
Every panel is checked before it reaches the next stage, so quality is built in from the first cut.
02
Embroidery
Signature details, stitched in-house.
Embroidery and detailing are handled in-house on multi-needle embroidery machines. Logos, motifs and decorative stitching are applied to flat cut panels before assembly, giving clean, accurate placement while keeping timelines and quality under one roof.
03
Stitching
Where cut panels become garments.
Our Stitching Department combines advanced automation with skilled craftsmanship, producing up to 40,000 pieces per day. VI.BE.MAC machinery and auto pocket setters support consistent quality and flexible production across diverse denim styles.
04
Dry process
Authentic wear, crafted by hand.
Before a garment reaches the laundry, our dry process team gives it character. Skilled technicians build abrasion, whiskers and distressing by hand, preparing every piece for the wash that brings the effect to life.
01
Hand sanding for natural abrasion and highlights
02
Grinding and destroy for frayed edges and rips
03
Whiskers placed to the approved look
05
Wet process · Laundry
Where denim gets
its character.
Our wet process laundry is where technology defines the finish. Computer controlled Yilmak and Brongo front loaders run programmed wash recipes for repeatable shades from one batch to the next.
Jeanologia e-Flow nano-bubble technology and ozone washing create vintage, bleached and faded effects with far less water, energy and chemicals than conventional washing, while Jeanologia EIM software scores the environmental impact of every recipe. Sustainable garment dyeing follows the same principle.
01
Yilmak & Brongo front loaders
Programmable industrial washers for consistent, repeatable results
02
Jeanologia e-Flow
Nano bubble finishing that replaces most of the water in the wash
03
Ozone Plasmagen
Ozone washing for bleached and faded looks with fewer chemicals
04
EIM by Jeanologia
Measures the water, energy and chemical impact of each wash recipe
Brongo front loaders
Jeanologia e-Flow nano bubble technology
06
Finishing
The final touch.
Raw denim takes its final form in our Finishing Department. Jeanologia laser and ozone technologies add precise, repeatable finishes, and skilled artisans complete each garment with careful detailing and inspection, transforming it into a market ready product.
01
Laser finishing
Jeanologia Laser Compact for precise, repeatable designs
02
Ozone finishing
Faded, vintage looks with minimal water and chemicals
03
Detail checking
Final inspection of every finished garment
04
Ready for inspection
Finalized and packaged as a market ready product
Laser · Jeanologia Compact HS3D
Ozone finishing
Market ready
QA
Quality assurance
Quality is built into every stage.
Our qualified quality professionals follow a zero tolerance approach to defects, conducting inspections throughout the manufacturing process rather than relying solely on final inspection.
01
100% panel inspection before stitching
02
Real time quality tracking through Smart MRT
03
Comprehensive fabric and garment testing
04
Final seam by seam inspection before packaging
05
Zero-tolerance defect standards across every stage
One roof
Production
Six integrated departments,
one purpose-built facility.
Cutting, embroidery, stitching, dry process, laundry and finishing work side by side, so every order moves from fabric to finished jeans without leaving our facility.
The cutting room
The sewing floor
The laundry
Pieces produced per day
Departments under one roof
Days average lead time
Platinum-certified facility
Quality and precision at every stage.
We integrate sustainable practices across our manufacturing to create high-quality denim with lower environmental impact.
Integrated operations
Cutting, embroidery, stitching, dry processing, laundry and finishing are managed within one purpose-built facility, helping reduce lead times and maintain consistent quality.
Advanced technology
CLO 3D, Gerber, Bullmer, VI.BE.MAC and Jeanologia systems support zero tolerance quality standards, from digital fit approval and raw panel inspection to final garment finishing.
Skilled craftsmanship
Trained teams follow ZDHC Level 3, MRSL and RSL compliant practices, supported by sustainable dyeing and washing technologies designed to reduce water, energy and chemical consumption.
Better denim starts with a better process.
Our sewing floor
Fabric inspection
Auto pocket setter
Ready to start your next denim program?
Send us your tech pack, quantities and timeline, and our team will plan sampling, production and delivery with you.
Passion for denim since 1999. Denim and knitwear, made under one roof in Lahore, Pakistan.
Company
What we make
- Denim division
- Knits division
- Manufacturing
- Technology
Responsibility
- Sustainability
- Certifications
- Code of ethics
- CSR projects
Contact
Glaxo Town, 20 km off
Ferozepur Road, Lahore
54000, Pakistan
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