INSIDE THE FACTORY

PRECISION APPAREL ENGINEERING.

Take a deep dive into our 8-stage manufacturing process in Sialkot, combining cutting-edge apparel machinery with artisan stitching standards.

PRODUCTION LIFECYCLE

8 STEPS TO APPAREL EXCELLENCE

Every garment manufactured at SALOSPORTS passes through our standardized 8-step quality protocol.

STAGE 01

3D CAD PATTERN & DIGITAL GRADING

Our pattern masters translate client sketches or Illustrator techpacks into digital CAD grading files, ensuring exact proportional scaling across size curves (Youth YS through Adult 6XL).

Optitex / Gerber CAD Grading

3D Digital Mockup Approval

STAGE 02

FABRIC SOURCING & GSM LAB TESTING

Athletic fabrics are inspected on our fabric inspection machines. We verify GSM density, 4-way elastane stretch recovery, anti-bacterial wicking, and pre-shrink stability.

Lab Tested 160 - 450 GSM Knits

Hydrophilic Dry-Wick Treatments

STAGE 03

PRECISION CNC & LASER CUTTING

Automated multi-ply fabric spreading and camera-guided CNC laser cutters eliminate human cutting variances, producing clean edges that prevent fraying during assembly.

Sub-Millimeter Edge Tolerance

Laser-Sealed Seam Margins

STAGE 04

4K DIGITAL HEAT SUBLIMATION

Using high-speed wide-format dye-sublimation printers and rotary heat presses at 210°C, inks gas-fuse into the polyester fibers for permanent, scratch-proof vibrancy.

Italian High-Density Pigments

Zero Surface Hand-Feel / Breathable

STAGE 05

TAJIMA EMBROIDERY & SCREEN PRINT

Computerized 12-head Tajima embroidery stations stitch 3D puff crests and metallic crests, while our screen printing carousels apply plastisol and reflective graphics.

3D Foam Raised Crests

Multi-Layer Tackle Twill Badges

STAGE 06

INDUSTRIAL SEWING & FLATLOCK ASSEMBLY

Our master seamstresses operate specialized flatlock 4-needle, overlock 5-thread, and coverstitch machines using high-tensile bonded polyester threads.

Chafe-Free Flatlock Seams

Bar-Tacked High Strain Points

STAGE 07

6-POINT QUALITY CONTROL AUDIT

Each finished jersey and hoodie is measured against spec tolerance sheets, checked for loose threads under 1000-lumen inspection lights, and ironed.

AQL 2.5 Sampling Inspection

100% Dimensional Verification

STAGE 08

BRANDED PACKAGING & GLOBAL DISPATCH

Items are tagged with custom brand hangtags, folded in branded polybags, packed in heavy corrugated export cartons, and shipped door-to-door via DHL / FedEx.

Custom Barcoded Polybags

Trackable DHL Air Express (4-6 Days)

PLANT HARDWARE

PRODUCTION MACHINERY

WIDE FORMAT SUBLIMATION

High-speed industrial printing lines with 4K piezoelectric printheads and rotary drum calenders.

MULTI-HEAD EMBROIDERY

Multi-needle computerized Tajima stations for 3D puff embroidery, metallic lurex threads, and badges.

JUKI & YAMATO STITCHING

Precision Japanese industrial sewing units delivering reinforced flatlock, coverstitch, and overlock seams.