The main strength of Nounou Bros is its vertical integration of the different phases of the industry, from yarn going all the way to the finished garment.
The company has a total of 600 well trained, experienced, and highly skilled workforce. While the garment production division has a monthly capacity of 200,000 pieces, the monthly capacity of fabric production is 250 tonnes.
Nounou Bros has production plants in five principal areas of the supply chain:
- Polyester yarn processing and intermingling
- Woven fabrics
- Knitted fabric production
- Dyeing and finishing of textiles
- Apparel manufacturing
Yarn texturizing is considered to be one of the first steps of the textiles manufacturing process. It takes the raw material, or POY, and transforms it into polyester yarns.
Nounou Bros’ yarn texturing unit has a daily capacity of 8 tons, with a fleet of 3 texturing and 5 FDY machines. This capacity ensures the maximum coverage of later processes in line such as knitting and garment manufacturing, and the extra capacity is dedicated for our clients.
Woven Fabric Production
Fabric formation is the backbone of the textiles industry, as it has the biggest variety of product range which provides the tools for producing a wide array of ready-made garments.
The whole range of fabric formation methods are used at Nounou Bros, ranging from weaving, circular knitting and warp knitting to flat knitting and narrow fabric looms. Nounou Bros’ fabric manufacturing machines have the capacity to produce 20,000 meters daily, including 15,000 meters from narrow fabric looms and 5,000 meters from an assortment of weaving machines.
Knitted Fabric Production
Fabric manufacturing through knitting has a total production output capacity of 10 tons per day. Circular knitting is considered to be the biggest power in the fabric formation process, having a daily capacity of 8 tons of fabric.
Additional machinery make fabric accessories such as jacket waistbands and polo shirt collars and cuffs. Warp knitting machines have the capacity to produce 2 tons per day out of 20 machines, with arrange of products such as dazzle, different mesh and interlining fabrics.
Fabric Dyeing and Finishing
Fabric dyeing, whether for cotton or polyester fabric (or blends), is the core of the dyeing industry. Super Textiles is a Nounou Bros company and its activities are dedicated for this purpose.
Our dye has a monthly production capacity of 85 tons. This covers all the dyeing requirements of the company and complements the vertical setup. The extra capacities are kept for serving external customers.
The finishing processes give the final touch to the fabrics after dyeing. They ensure the fabric weight, dimensions, softness and hand feel are according to customer requirements.
Moreover, some extra effects such as brushing, sanding, shearing (for velour fabrics) are also available. New finishing effects are continuously integrated within the dye house facilities to ensure the latest trends in fashion are available. In both the dyeing and finishing processes, a very strict quality process is applied to ensure the customers receive exactly what they requested.
The garment manufacturing department covers several stages, from fabric inspection, cutting, bundling, printing, embroidery, sewing to finishing and packing. A quality assurance team inspects every production step to ensure defect-free garments.
Before any fabric is moved to the next step of the production process, it undergoes rigorous inspection to ensure that it meets the designated quality control standards. Any necessary applications are made prior to the actual sewing. Garments are then placed on controlled production lines managed by skilled workers. The machinery used is intended to ensure the best possible quality of the finished product. Trained staff and machines work together to maintain a reputable standard of the factory’s merchandise.
After sewing, the garment is given to a team of workers who carefully finish the piece. Garments are randomly inspected one final time before tag insertion and packing.