Manufacturing & Infrastructure

Nine steps between cotton and container.

Le Merite operates an integrated production chain — from fibre selection through spinning, doubling, weaving and processing to export dispatch.

Process

The production line, end to end.

Fibre selection and lot-wise inspection of incoming cotton before issue to production.

Opening, cleaning and blending to remove trash and prepare a uniform lap.

Fibre individualisation and impurity removal — the foundation of yarn evenness.

Ring spun carded, combed and compact yarn Ne 8/1 to Ne 60/1, plus open end OE 6/1 to OE 30/1.

SAVIO COSMOS TFO with 2,400 spindles and PEASS SCHLAFHORST winding, up to 3 ply.

114 Tsudakoma air-jet looms; process house with singeing, mercerizing, dyeing, printing and finishing.

Texmech inspection at 340 cm width, in-process monitoring and lot-wise release.

Hydraulic bale pressing, jumbo roll batching, pallet making and customer-specific marking.

Documentation and container stuffing for shipments to almost 37 markets.

Machinery

Weaving: 114 Tsudakoma air-jet looms — 48 at 190 cm, 30 at 210 cm, 36 at 290–340 cm.
TFO: SAVIO COSMOS — 10 machines, 240 spindles each, 2,400 spindles total, max speed 11,500.
TFO winding: PEASS SCHLAFHORST PPW-AV, Navsari — 4 machines, 120 drums, max 1,200 mpm, up to 3 ply.
Inspection: Texmech, Ahmedabad — width 340 cm.
Compressed air: Atlas Copco 55 GE — 4,900 CFM, 14 compressors.
Humidification: Luwa humidity plant.
Process house: Singeing, de-sizing, mercerizing, CBR, jigger, HTHP closed jigger, jet dyeing, 12-colour printing, stenter, sanforizer, calendering.
Baling: Hydraulic pressing machine for bales, batching motion for jumbo rolls, pallet making platform.