Aero Cotton

Manufacturing

Eight gates.
No shortcuts.

Every programme passes the same eight stages — each with a defined specification and an owner. Capacity figures and machinery counts are shared on request during enquiries; this page describes how the mill thinks, not just what it owns.

The process

Material to carton, in order.

  1. 01

    Material selection

    Cotton is chosen by staple, grade and hand-feel for each programme. Yarn is specified before the first warp is dressed — the cloth is decided before it exists.

  2. 02

    Weaving

    Looms are set to buyer tolerance: weave structure, density, width. First-piece approval is standard before a run proceeds.

  3. 03

    Dyeing

    Reactive dyeing to buyer lab-dips, with colourfastness targets specified per programme. Shade approval happens at the lab, not after the fact.

  4. 04

    Cutting

    Panels are cut to specified dimensions with documented allowances, so a towel ordered at 70 × 140 cm arrives at 70 × 140 cm.

  5. 05

    Stitching

    Hems, borders and bindings are sewn to stitch specification. Edge work is where premium cloth is won or lost, and it is checked as its own stage.

  6. 06

    Finishing

    Singe, mercerise, calender — finishing is applied only as specified, because a finish that was never asked for is a defect with good lighting.

  7. 07

    Quality control

    Piece-by-piece inspection at the checking tables: dimensions, weight, shade, construction, and appearance. Failures are mended or pulled, never shipped with a note.

  8. 08

    Packaging & export

    Export-grade packing, buyer-labelled, container-loaded and documented in-house. The carton that leaves Karur is the carton that opens in the buyer's warehouse.

Scroll — each stage is one gate the cloth must pass.

Quality control

The spec sheet is the contract.

Buyers receive what was specified — GSM, dimensions, shade, construction — with inspection records available per programme. If a specification cannot be met, we say so before the order, not after the shipment.

  • Specifications agreed in writing before weaving begins
  • In-process checks at weave, dye and finishing stages
  • Final piece-by-piece inspection before packing
  • Buyer inspections and third-party audits welcomed

Custom manufacturing

Bring a spec sheet, a sketch, or a swatch.

Buyer palettes, private-label weaving, custom constructions and packaging are part of the mill's normal work — not a special favour.

Discuss a programme