PRODUCTION
From Development to Delivery
All stages of our production are monitored through our advanced ERP system to ensure a smooth and transparent workflow. Quality control is integrated into every stage of the production process, in addition to the final inspection of finished garments. From development to final delivery, we continuously evaluate and improve our production processes to maintain efficiency, consistency, and high product quality. Our dedicated quality team ensures that every garment is sourced, developed, manufactured, and delivered in line with our strict quality standards.
Sampling & CAD Department
Sampling is the product development stage. It is a process by which a small number of garments are made so as to match the buyer requirement and to get approval from the buyer so as to start off the production. The sampled garments represent the accuracy of the patterns and quality of production skills and techniques. The samples not only serve the purpose of communicating correcty with the buyer regarding their styles and products, but it also helps to calculate the fabric consumption along with that thread and other accessories used.
Our sample room prepares garments based on the technical specifications and requirements provided by the buyer in the tech pack. Typical sample types include: Proto Sample, Fit Sample, Pre-Production Sample, Pre-Size Set, Size Set, Salesman Sample and Shipment Sample
We are using the latest GERBER AccuMark Pattern Design System (PDS) a sophisticated computer-aided system for pattern design and editing. Our CAD department is responsible for the following functions: Determining cutting average for costing, Making the most efficient cutting marker, Development and alterations of patterns, Development of size set pattern by grading, Positioning of embroidered and printed items, Digitizing the pattern.
Laboratory & Quality Testing Department
The Laboratory & Quality Testing Department plays a critical role in ensuring that all products meet the required quality standards before and during production. It is a process where fabrics and garments are tested under controlled conditions to evaluate their performance, durability, and compliance with buyer expectations.
Our laboratory focuses primarily on physical testing methods to assess fabric and garment behavior throughout the production cycle and after finishing processes. These tests help us identify potential issues at an early stage and ensure consistent product quality.The main testing procedures include: fabric shrinkage and dimensional stability, twisting and spirality control, washing performance and post-wash appearance evaluation, color and print durability, as well as embroidery quality assessment. Through these tests, we ensure that garments maintain their shape, appearance, and performance after repeated use and care.
In addition, our laboratory supports production by verifying print and embroidery applications, checking fabric consistency, and monitoring overall product quality. This systematic approach allows us to minimize risks, maintain high standards, and deliver reliable products that meet both technical specifications and customer expectations.
Cutting Department
Spreading: Spreading is the process of superimposing plies of fabric on a horizontal table in a manner, which permits these plies to be cut simultaneously into product components acceptable for assembly. The spreading is done either manually or automatically by the spreading machine.
Automatic Cutting: The lay is cut automatically via our latest technology automatic Cutter system. The system uses the pre-loaded nested patterns which are prepared via Automated Nesting Software and is 5 times faster than manual cutting.
Manual Cutting: Electrically powered straight knife cutting machines are used for manual cutting. The machine is moved through the lay following the pattern lines of the marker and there ciprocating blade cut the pieces of the fabric progressively. Notches are also added. For smaller components like collars, ribs and etc that need high accuracy, band knife-cutting machine is used. It is a non-portable cutting device which cuts the fabric as it is passed across the blade.
Jacquard, stripes and checks cannot be spread with the spreading machine due to requirements of matching so they are spread manually.
Embroidery Department
The embroidery department receives the cut part of the garment, style and the embroidery details in the form of the hard copy format. The design is scanned and digitized (punching) using the Embroidery CAD software and saved as the machines format. After loading the digitized design to the samoling machine, a sample is done before going into production. After confirmation of the sample in terms of the positioning, thread colors, quality and backing materials, the bulk production starts. At Akcakaya Textile, there are 5 embroidery machines (Barudan and Tajima), 2 of them are with double sequin apparatus and 1 applique laser cutting system.
After the embroidery is been done for the first set of the cut parts they are then sent to the trimming and the checking section of the embroidery department. After checking and finalizing the QC embroidered items are sent back for stitching.
Sewing Department
The Sewing Department is one of the most critical stages of the production process, where garments begin to take their final shape. Cut components are transferred from the cutting department to the production lines, where skilled operators assemble each piece with precision and care.
Akcakaya Textile operates its own in-house stitching unit, ensuring close control over quality, consistency, and production standards throughout the sewing process. Each garment is constructed through a series of specialized sewing stations, where different parts such as sleeves, collars, and pant legs are individually assembled. Through this structured and controlled process, all components are brought together to create the final garment, reflecting both technical accuracy and high production quality.
Finishing Department
The Finishing Department is the final stage of the production process and plays a crucial role in the overall appearance and quality of the garment. At this stage, each product is carefully prepared for delivery, ensuring it meets the required standards and customer expectations.
This department includes a series of essential operations such as trimming, detailed inspection, semi-pressing, final pressing, tagging, and packing. Every garment is thoroughly checked to ensure it is free from defects and meets the approved specifications.
Our packing processes are carried out according to customer requirements and may include solid packing, ratio packing, or mixed packing. Through careful handling and attention to detail, the Finishing Department ensures that all garments are presented in their best condition, ready for shipment.
