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The Rajlakshmi Cotton Mills Private Limited

A. J. C. Bose Road, Kolkata, West Bengal

| GST  19AAACT9363L1ZP

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Fabrics

Leading Manufacturer of Carding & Spinning Cotton Yarn, Dyeing and Printing Fabrics from Kolkata.

Carding & Spinning Cotton Yarn
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In the textile business, everything starts with yarn. Our top quality organic Cotton is sent to the spinning mill to be spun into yarn. The yarn will define the overall quality of the finished products, so this is a very important step in the process.
The first stage is in the opening room. Here, bales are opened and laid in a line on the floor, side by side, near a cotton opening machine. This machine travels along the line of opened bales, pulling fibers to be sent to a mixing machine and then on to the carding system.

Carding is the process of pulling the fibers into parallel alignment to form a thin web. High speed electronic equipment with wire toothed rollers perform this task. The web of fibers is eventually condensed into a continuous, untwisted, rope-like strand called a sliver
These slivers then continue to a combing machine. Here, the fibers shorter than half-inch and impurities are removed from the cotton. 

This process makes the sliver smoother so more uniform yarns can be produced. The drawing or pulling of this sliver is next. 
The sliver is drawn out to a thinner strand and given a slight twist to improve strength, then wound on bobbins (spools wound with the thread-like product for storage). Having completed this process, it is now called roving. The roving bobbins are now ready for the spinning process. 

Spinning is the last process in yarn manufacturing. Today's mills draw and twist the roving into yarn and place it on bobbins. They do this quite efficiently. A large, modern mill can produce enough yarn or thread in 30 days to wrap around the earth 2300 times or go to and return from the moon 235 times. With the use of automatic winding, the yarn bobbins are transferred to larger bobbins called cheese cones. These cheese cones can be stored until they are needed for weaving and knitting.

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Dyeing
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Dyeing

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We use low-impact, fiber-reactive dyes for dyeing all our products. Our dyes are safe, GOTS certified and "low impact," which means that we use less water, less heat and produce less waste runoff than regular chemical dyeing processes. Recent advances have created fiber-reactive dyes with colors that are brighter and richer than previously available, and they provide excellent colorfast properties on cotton. Fiber-reactive dyes have become the dye choice for many organic clothing manufacturers because they offer a diverse palette of vibrant colors. They contain no heavy metals or other known toxic substances, and they meet all European Union criteria for eco-friendly pigments.

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Printing Fabrics
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Printing Fabrics

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Applying color patterns and designs to fabrics has been done since 5000 BC (Egyptian findings) and continues to be popular today for textiles of all sorts. It is, however, one of the most complex textile operations because of the many variables and the need for precision.

Printing is carried out after the dyeing or pre-treatment of the fabric. Dyes or pigments are applied locally to produce the artistic arrangement of various motifs in one or several colors. To ensure that the dyes stay separate from one another and remain fast to the fabric, a strong bonding is formed between dyes and fabric.

There are two main types of printing on fabrics, all-over rotary printing on both woven and knitted fabrics and screen printing. 
Rotary printing is used when large quantities of fabric need to be printed with the same design (ex: sheets and other home linens, large runs of garment fabrics…). This method produces more unified, homogenous effects in the printing, as compared to screen printing. A large cylinder applies a dye paste to the fabric, which has been introduced between the engraved rollers, thus reproducing the desired design. This process is the most appealing for printing designer and fashion fabrics because of the high quality that can be achieved.

Screen printing is a very popular technology in use today for producing placed prints on fabric. This method involves a porous mesh stretched tightly over a frame. Proper tension is essential for accurate color registration. A stencil on the screen defines the image to be printed in each color.

RCM's in-house screen printing unit prints thousands of T-shirts on a daily basis, as well as motifs on babywear, home textiles, promotional items and other garments.

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