State-of-the-Art Knitwear Facility
We transform fiber into global-market garments using modern machinery, automated cutting layouts, and a highly skilled workforce of 250+ artisans.
In-House Capabilities & Engineering
At Lotus, we control every manufacturing step except spinning and dyeing, which we outsource to certified, audited local partners under our strict QA supervision. This ensures we maintain cost-efficiency while keeping oversight of quality.
Facility Footprint
75,000 Sq. Ft. built-up industrial area located in Tirupur, India's leading knitwear hub. Custom designed for linear manufacturing efficiency.
Stitching & Sewing
180+ high-speed modern sewing machines (Juki, Pegasus, Siruba) including overlock, flatlock, and automatic collar attachment setups.
CAD & Cutting Desk
Computer-aided marker planning (Optitex CAD) and automated fabric spreading to ensure 98% yield and minimal raw material wastage.
In-House Sampling
Dedicated sampling room with 15 master tailors, producing prototype fits and counters within 7-10 days of tech pack sign-off.
Annual production capacity exceeding 4.5 million knitwear units.
180+ High-Speed Precision Sewing & Flatlock Lines • Tirupur Facility
Program Operations & Timelines
Sampling Lead Time
7 to 10 Business Days
Requires official PDF tech sheets or physical sample.
Production Lead Time
45 to 60 Days (Post PP Seal)
Varies based on fabric blend and local dye mills schedule.
Minimum Order Quantity
500 Pcs (Cottons) / 1,000 Pcs (Blends)
Basic all type of Cottons will start with 500 pcs per color. Bamboo organic and Pima blends will be 1,000 pcs per color.
Our Production Process Flow
End-to-end coordination of client garments from initial CAD tech pack review to final sea/air port dispatch.
Design & Tech-Pack Review
Our CAD department reviews buyer specifications, measurement charts, and fabric constructions, verifying tolerances before prototyping.
Yarn & Fiber Sourcing
Sourcing premium ring-spun organic cotton, bamboo, polyester, or modal fibers tested for tensile strength and staple consistency.
Sampling & Approvals
Creating fit samples, size sets, and pre-production (PP) samples. We run shrinkage, spirality, and GSM tests prior to official client seal.
Precision Cutting
Relaxing knit fabrics for 24 hours to stabilize fibers. Automatic spreading and computerized pattern layout minimize cutting waste.
High-Speed Sewing
Operations are divided into modular lines. Flatlock, overlock, and blind hem stitches are applied matching buyer stitch-density instructions.
Quality Control (AQL 2.5)
Inline checking, end-of-line inspections, and final AQL 2.5 audits. Garments pass through metal detection tunnels to ensure total safety.
Packing & Presentation
Steam pressing, custom tag attachment (hangtags, UPC barcodes, price stickers), and individual polybag packaging following buyer layout specs.
Global Logistics & Shipping
Carton packing in heavy-duty shipping containers. Coordination with sea freights via Tuticorin/Chennai ports or air shipment via Bangalore.
Ready to Discuss Your Manufacturing Program?
Connect directly with our Tirupur production desk. Submit your specifications, target volume, and fabric blends to receive an official costing within 1 business day.
Submit Manufacturing RFQ