Sherif Moursi Companies (Borg El Arab) | lab, production, embroidery, sewing

 lab, production, embroidery, sewing

Alexandria Clothing Company is a vertical knits operation.
Production facilities include:
Knitting
Dying
Cutting
Printing
Embroidery
Sewing
Design and Development

KNITTING DEPARTMENT

The knitting department consists of 57 top quality circular knitting machines. Also available in-house are cord knitting machines, elastic knitting machines and collar machines.

Fabric types we produce:
Single jersey from 120gms/sqmt up to 360gms/sqmt. (With and without elasticise)
Interlock from 160gms/sqmt up to 380gsm/sqmt. (With and without elasticise)
2 thread fleece from 200gms/sqmt up to 300gms/sqmt. (With and without elasticise)
3 thread fleece from 240gms/sqmt up to 400gms/sqmt.
Rib from 140gms/sqmt up to 400gms/sqmt (With and without elasticise)
Pique from 160gms/sqmt up to 360gms/sqmt. (With and without elasticise)
French Terry from 150gms/sqmt up to 300gms/sqmt.
Our range also includes electronic jacquard in single & double jersey and eyelet capability in rib.
Various needle outs and other constructions are also available, feeder striper is available on all machines and engineer stripe on single jersey, pique & 2 thread fleece.
Although cotton and cotton/elasticise are our key fabrics we also cover poly/cottons, polyesters, viscose and nylon fabrics with and without elasticise. Alexandria Clothing Company is an approved knitter/garment manufacturer by Dupont and is regularly working on developing new fabrics .
Average production capacity is 15 Tons/ day.

DYEING DEPARTMENT

The dyeing department has the capability to dye atmospheric and high temperature dyeing as well as finish fabrics in tubular or open width form.
Dyeing of cottons, polyesters, nylon, and viscose is all done in-house.
All fabrics have passed echotex testing and this is something the company has been maintaining regularly since 1998.
Silicon, enzyme and various other finishing methods are available.
Alexandria Clothing Company also has one of the few Tubetex finishing machines available in Egypt. This gives the capability of compacting fabrics up to 30% hence achieving a much softer hand feel and reducing shrinkage problems.
Machine range is 25 kilos minimum & 1000 kilos is the largest dyelot.
Average production capacity is 14 Tons/ day.

LABORATORY

Accredited for NEXT and Debenhams.
LACE accreditation to follow: for BHS, TESCO, Wallmart, Sainsburys, Matalan

Tests we can perform:
- Colour Fastness to Washing
- Colour Fastness to Cold Water
- Colour Fastness to Perspiration
- Pilling Resistance
- Shrinkage
- Spirality
- Light Fastness
- pH
- Print Durability
- Garment Assessment After Wash
- Smoothness Appearance after wash
Colour Lab:
Data colour Auto lab SPS Solution maker – ensures all dyes are made up to the correct strength and in the correct manner
4 x Ahiba Top Speed Laboratory Dyeing machines
Auto lab T88 – 80 dye automatic laboratory dispenser with 8 auxiliary chemicals.
Data color conditioning cabinet to ensure all fabric measured on the spectrophotometer are under standard conditions of temperature, humidity and light exposure before measurement on the spectrophotometer.
Data color SF600 spectrophotometer with full shade match prediction software.
Verivide Light box to assess shades. It includes INCA, UL3000, Daylight 65, CWF, TL83 and UV.
Data color recipe management software.

CUTTING DEPARTMENT

All patterns and marker making are carried out on our Gerber system. The cutting room has the capability to cut open width and tubular fabrics.
In-house are three 30 meter long open width cutting tables and an automated Gerber cutter to insure maximum efficiency and accuracy. There are also four 30 meter tubular cutting tables with manual laying up machines.
Cutting capacity is 50,000 pieces per day.
The cutting department is responsible for coordinating the movement of all orders between printing, embroidery, and sewing. It is where the final bill of materials for each order ( accessories, sewing threads, hangers, etc.) is checked and sent to sewing.

EMBROIDERY DEPARTMENT

Our embroidery plant consists of 174 heads of embroidery, with a capacity of 23,500 stitches per minute and up to nine colours of thread.
We have 12-head, 10-heads, 6-heads, and 3-heads machines as well as two 1-head machines used for sampling.
Various stitch techniques and applications are carried out, from all panel embroidery to small logos, as well as appliqué embroidery.
All films are done in-house which eliminates time wastage and enables production to adapt to the customers requirements.
There is also a continuous transfer machine in the embroidery department that allows for diamante, studs, prints, etc. to be transferred onto panels.

SEWING DEPARTMENT

Our sewing department is spread over two plants. There are 7 units in the Alexandria plant and 2 units in the Borg El Arab plant with an average total of 30 lines.
The average sewing capacity is 50,000 pieces per day.
Specialized machinery available includes: picot edging, elastic & trim attachment, piping, studding , button & button hole & various binder attachments.
We maintain a strict needle policy and have a conveyor belt metal detector in house, hand held detectors are also available in each unit.
Our garment range includes: - T-shirts, Vests, Shorts, Leggings, Jackets, Sweatshirts, and Dresses.

DESIGN AND DEVELOPMENT

The design department has its own dedicated staff & sewing line. It has the ability to turn around 20 styles/day.
In order to maintain an edge we have found it essential to have an in-house team of designers. This enables us not just to carry out our customers sampling requests and pricing but to benefit from having this vertical operation under one roof.
Our European design team work closely with our sister company, Basic Thinking, in the UK to stay ahead with trends thus enabling us to remain fashion conscious and competitive.

QUALITY CONTROL SYSTEM

There are quality control checks throughout each department in the factory. The quality control systems are monitored through the Arel System. For example, fabric cannot exit the dyehouse without all quality results being entered and meeting the specifications. In the past each department had its own quality control department. Recently we have introduced a separate quality control department that is responsible from yarn to the end product.
Systems Used:
4 point system
Continuity cards
Panel Inspection
AQL 2.5 system
Lab Tests

We are presently working toward our ISO 9001 and 14002 certification and we should be fully certified by June 2007.

MANAGEMENT

There are also several different behind the scenes departments that work together in conjunction with senior management to ensure the smooth operation of the factory:
Production Planning and Control
Merchandisers
Human Resources and Administration
Accounting
Shipping
Purchasing
Costing
Warehouses

The entire factory is linked via computer terminals and a production system known as AREL. The AREL system allows all users to monitor the movement and production rates of all orders at any time and in any department.

The garment industry is a constantly changing business that requires Alexandria Clothing Company to remain competitive and offer customers the wider range of capabilities and embellishments that the change in fashion demands.

Over the course if 2007 there are several new additions that we anticipate:
Peaching machine
Laser cutting machine for embroidery
Garment Washing Machines
Additional 200 sewing machines
All Over Printing Machine
Yarn Dye
We are also currently building an enlargement to the factory to accommodate the growing business and the increased need for storage space.

We have a strong and efficient merchandising and planning team that continuously allow the factory to jump from strength to strength.
All production control and monitoring is computerized.
We have the largest embroidery and printing plants in Egypt.
We have an open factory policy and our customers are welcome at any time to view their production.
It is with complete confidence that we can say that Alexandria Clothing Company is one of the most cooperative, flexible, and innovative companies in the region.

www.alexandriaclothing.com.eg/
Alexandria Clothing Company (ACC), one of the Dice Group Companies is a vertically integrated jersey wear manufacturer based in Alexandria, Egypt.