RCM

A J C Bose Road, Kolkata, West Bengal

Lengthwise rows of these loops, comparable to the warp yarn in woven goods, are called wales. Crosswise rows, comparable to filling yarns, are known as courses. There are numerous similarities in knitting done by hand and machine, but there are also some marked differences. RCM's cotton knits are produced on circular machines which have needles fixed to the rim of a rotating cylinder. As the cylinder turns, the needles work their way from stitch to stitch producing a tubular fabric. Its width is regulated by the size of the cylinder, which usually ranges from 9 to 60 inches in diameter. Depending on the width of fabric desired, a modern knitting machine might use over 2, 500 needles. Instead of a single cone of yarn, a knitting machine may have up to four cones per inch of fabric width. For example, a machine with a 32-inch cylinder can have over 2, 700 needles and 128 cones of yarn feeding simultaneously. These are typical statistics for a machine used in making underwear knits, but figures vary according to the type of machine used and the fabrics produced. The flat knitting machine is another basic type. Designed with a flat bed, it has dozens of needles arranged in a straight line and produces a knit fabric that is flat, similar to woven fabric. A flat knitting machine makes over one million stitches a minute, and can be set to drop or add stitches automatically in order to narrow or widen the fabric at certain points to conform to specific shapes. Knitting machines can be programmed to produce a wide variety of fabrics and shapes.

Today, cotton is considered the most important natural fiber used in the textile industries worldwide, amounting to 40% of the textile production. India is among the three leading cotton-producing countries (with USA and China).Cotton plants really are beautiful! There are lovely flowers and the cotton bolls are absolutely awesome. Did you know that the color of the flowers is very significant? White flower / white bloom — The first day a bloom opens it is white or a creamy yellow color. In the afternoon, the pollen is released and as it self-pollinates. Pink flower / pink bloom — Once pollinated, the flower begins to turn pink, becoming a bright fuschia in a few days. Young boll — As the pink bloom dries down, the young boll pushes its way up, forcing the pink bloom to fall off as a tag. The boll (it looks like a nut) continues to grow as the fiber and seed grow. Cracked boll — As cotton fiber matures, cotton bolls open slowly as the bracts dry and separate. Open boll — This is the part of the plant that most people think of when they think of a cotton plant… it’s what we harvest. And it looks like the cotton balls in your bathroom cabinets.

The importance of Organic Cotton

People are starting to know about the health benefits of buying organic food and using organic cleaning products, but what about organic materials in textile? If you are an animal lover, care about what goes on your body or are concerned with the welfare of others, take note: promoting organic fabrics has a major positive impact on your health and the health of our planet. From a fashion standpoint, Organic clothing now follows all the latest style trends. This means that there are now brands available which offer your favorite styles produced in organic cotton! However, the biggest benefit of organic cotton remains the environmental aspect: the crops are not treated with pesticides, insecticides, herbicides and Genetically Modified Organisms. These substances are harmful to farmers and workers, to us as consumers, and to entire wildlife eco-systems. Organic cotton is grown in a way that uses methods and materials that lessen the impact on our environment. An important difference with organic growing systems is that they replenish and maintain soil fertility and build biologically diverse agriculture. Organic cotton uses far less water too.

 

Unfortunately, today, less than one percent of all cotton grown is organic.

More and more brands and fashion houses are committing to organic materials. Some very large and well-known brands, as well as dozens of smaller brands have also championed organic materials, all kinds of fabrics are available now in sustainable organically grown cotton. Consumers need to be aware that their choices can literally save the lives of our farmers, our rivers and streams and give our youth a chance to grown up in an unpolluted environment.

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 sliverThese 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.

What parent wouldnt want to protect their newborn child against pollution and the contact of harmful chemicals? Everyone, for sure! This explains the rapid growth of the baby and kids organic garment market. If you are looking to create a line of baby and childrens clothing, trendy newborn baby garments, or unique newborn baby gifts; you are in the right place! RCM works with a number of designers in Europe, US and Australia and to produce top of line infant and kids wear. All of our organic baby clothes are made from GOTS certified organic cotton, and dyed with eco friendly low-impact dyes. Choose from wide selections of fabrics to make your line of newborn baby clothes, baby onesies, kimonos, bedding, organic cotton cloth diapers, baby caps, booties, etc, as well kids wear in a wide variety of trendy knit and woven fabrics.

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.

Weaving is the oldest method of making yarn into fabric. While modern methods are more complex and much faster, the basic principle of interlacing yarns remains unchanged. On the loom, lengthwise yarns called the warp form the skeleton of the fabric. They usually require a higher degree of twist than the filling yarns that are interlaced widthwise. Traditionally, cloth was woven by a wooden shuttle that moved horizontally back and forth across the loom, interlacing the filling yarn with the horizontally, lengthwise warp yarn. Modern mills use high-speed shuttleless weaving machines that perform at incredible rates and produce an endless variety of fabrics. Some carry the filling yarns across the loom at rates in excess of 2, 000 meters per minute. The rapier-type weaving machines have metal arms or rapiers that pick up the filling thread and carry it halfway across the loom where another rapier picks it up and pulls it the rest of the way. Other types employ small projectiles that pick up the filling thread and carry it all the way across the loom. Still other types employ compressed air to insert the filling yarn across the warp. In addition to speed and versatility, another advantage of these modern weaving machines is their relatively quiet operation. There are three basic weaves with numerous variations, and cotton can be used in all of them. The plain weave, in which the filling is alternately passed over one warp yarn and under the next, is used for gingham, percales, chambray, batistes and many other fabrics. The twill weave, in which the yarns are interlaced to form diagonal ridges across the fabric, is used for sturdy fabrics like denim, gabardine, herringbone and ticking. The satin weave, the least common of the three, produces a smooth fabric with high sheen. Used for cotton sateen, it is produced with fewer yarn interlacings and with either the warp or filling yarns dominating the "face" of the cloth. In some plants, optical scanners continuously monitor fabric production looking for flaws as the cloth emerges from the weave machine. When imperfections appear, computers immediately print out the location of the flaw so that it can be removed later during fabric inspection.

Grey Woven

The variety of fabric weave includes, Sheeting, Canvas, Satin, Drill, Twill, Gabardine, Herringbone and Oxford Weave. Our weaving partners are equipped with the most modern looms, providing fabrics in widths ranging form 160 cms to 360 cms.

Thick and super absorbent towels and bathrobes that your customers will love to buy for their luxurious softness. Different finishing is available on towels and weights go from 350 to 420 GSM. The long staple cotton can be woven to make waffle textures for towels and bathrobes or knit into velours, interlock or a plush terry loops to create a soft silky feel and promote maximum absorbency. Selection of towels and bathrobe materials:

VELOUR: Like the grandest spa wrap, a velour robe is a sumptuous pairing of plush terry on the inside and silky velour outside. Thick and warm, it is at the top of the line in bathrobes.

TERRY: Lighter than velour, it is none-the-less thick and plush, making it ideal for cool climates and as a spa robe.

INTEcomfyRLOCK: Cool and , in 190 GSM jersey interlock, the smooth texture is comfortable next to the skin and the interlocked knit provides stretch for added comfort. Ideal for warm climates and everyday wear.

WAFFLE WEAVE: When a terrycloth robes seem too thick, too heavy, or too warm, waffle weave bathrobes are like an excellent choice. Thinner and lighter than terry, the waffle fabric with its crisscrossing texture is great for warm climates and super quick to dry.

RCM produces several lines of home textiles rooted in nature. The towels and bedding are made from 100% certified hand-picked organic cotton, which undergoes a process to guarantee the high quality that comes out of our factory.

BED LINENS

RCM sheeting fabric (Sateen and Percale), after the cotton is grown, harvested, washed, spun into thread and woven into large sheets of fabric. Sateen sheets come in 250 and 325 thread count and percale in 220. We also do prints and jacquards.

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.

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.