A detailed walkthrough of all 13 stages of t-shirt manufacturing — from yarn spinning and knitting to dyeing, cutting, stitching, printing, quality control, and export packing. Based on the actual production workflow at a Tirupur factory.
Understanding the t-shirt manufacturing process helps buyers set realistic expectations for lead times, quality standards, and pricing. Here is a complete walkthrough of all 13 stages of t-shirt production at Esplandea Incorporation's Tirupur factory.
Cotton yarn is sourced from spinning mills in Coimbatore and Salem, Tamil Nadu — the heart of India's cotton spinning industry. We use combed cotton yarn (Ne 30/1 to Ne 40/1) for standard t-shirts and ring-spun yarn for premium products. Yarn is tested for count, strength, and evenness before acceptance.
Yarn is knitted into fabric on circular knitting machines. Single jersey (for standard t-shirts), pique (for polo shirts), and interlock (for premium t-shirts) are the main fabric structures. Knitting speed: 800–1,200 RPM. Fabric GSM is controlled by adjusting machine tension and yarn count.
Grey fabric is dyed in jet dyeing machines using reactive dyes for cotton. The dyeing process takes 6–8 hours per batch. After dyeing, fabric is treated with softener and anti-shrink agents. Colour matching is done using spectrophotometers to achieve Pantone accuracy within ΔE 1.0.
Dyed fabric is compacted to control shrinkage (AATCC test method 135). Compacting reduces residual shrinkage to less than 5%. Fabric is then inspected for defects using a 4-point inspection system.
Patterns are created using CAD software (Gerber or Lectra). Patterns are graded across all sizes (XS to 4XL). Marker efficiency (fabric utilisation) is optimised to minimise waste — typically 85–90% efficiency.
Fabric is spread in layers (up to 100 layers) and cut using automated cutting machines. Cutting accuracy is within ±2mm. Cut parts are bundled by size and style for the sewing floor.
Cut parts are assembled on the sewing floor using specialised machines: overlock (serger) for seams, flat-lock for hem and sleeve attachment, and cover stitch for collar and cuffs. Stitch density: 12–14 stitches per inch for standard seams.
Screen printing, DTG, embroidery, or sublimation is applied after sewing. Screen printing requires a separate curing process (160°C for 90 seconds) to fix the ink. Print quality is inspected for registration, colour accuracy, and coverage.
Garments are steam-pressed, folded, and inspected. Labels (woven, printed, or heat transfer) are attached. Hang tags, size stickers, and barcodes are applied as per buyer specifications.
Final QC inspection is conducted using AQL 2.5 sampling plan. Inspectors check measurements, stitching, print quality, colour, and finishing. Defect rate target: less than 2%.
Garments are packed in individual polybags, then packed in export cartons. Carton markings include: buyer name, style number, size, colour, quantity, and country of origin.
Third-party inspection (SGS, Bureau Veritas, or Intertek) is conducted for orders above $20,000. Inspection report is shared with the buyer before shipment.
Goods are loaded into containers at the factory. Export documentation (commercial invoice, packing list, bill of lading, certificate of origin) is prepared. Sea freight from Tirupur to major global ports: 18–35 days.
The t-shirt manufacturing process involves 13 stages of precision and quality control. Esplandea Incorporation has mastered this process over 15+ years of export manufacturing. Contact us for a factory visit or free quote.