Factory – AVL

Factory Details

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Area Summery

Overview

Our facility proudly upholds the highest industry standards, including certifications from OEKO-TEX®, GOTS, OCS, GRS, and RCS. We are also audited and certified by SEDEX and have met the rigorous criteria of the Higg Index and ZDHC for sustainable practices.

Total Factory Premise Area

1,54,251 Sq. ft.

Total Green Area

66,140 Sq. ft.

Total Structural Area

88,111 Sq. ft.

Functioning Seamlessly

The factory premise is meticulously designed to support a lean production system. It impeccably integrates production units, quality control and testing facilities, utility and support services, and inventory management with administrative functions.

This holistic approach optimizes production efficiency, reduces lead times, and streamlines the production process across a diverse range of products.

Inside Our Optimally Designed Production Hub

The factory’s structural design, covering an area of 2,48,503 Sq. ft., is strategically engineered to enhance production capacity. It encompasses four key components: Production Line, Quality Control and Testing Unit, Utility and Support Services, and Administrative and Welfare Areas.

Area

Floor area 14,000 Sqt with a capacity of 11 tons per day. There are 19 circular Knitting & 8 Flat Knitting Machines with a capacity of 8500 pieces per day.

Production Line
Quality Control and Testing Unit
Utility and Support Unit
Warehouse and Storage
Administrative and Welfare Areas

Unit Name	Area (sq. ft.)
Knitting Unit	14,000
Dyeing Unit	8,500
Knit Garments Unit	78,500
Woven Garments Unit	22,300
Print Unit	5,000
Total Area	57,650

Unit Name	Area (sq. ft.)
Lab Unit	14,000
Total Area	14,000

Unit Name	Area (sq. ft.)
Utility Unit	940
ETP	5,200
Total Area	6,140

Unit Name	Area (sq. ft.)
Men's Formal Shirts	27,523.76
Men's Formal Shirts	18,162.11
Total Area	46,135.87

Unit Name	Area (sq. ft.)
Admin	1,050
Total Area	1,050

Facility Breakdown (Knitting Unit)

Knitting Unit

AVL’s knitting unit is powered by advanced European-standard machinery. Spanning 14,000 sq. ft., it delivers an impressive 11 tons of production capacity per day. Additionally, our 8 flat knitting and 19 circular knitting machines, capable of crafting intricate jacquards, plain, stripes, and self-designs, produce up to 8,500 pieces daily, ensuring precision and quality.

Knitting Equipment
Knitting Lab Equipment

Machine Type	Manufacturer	Country of Origin	Qty
Auto Stripe Circular	Mayer & Cie	Germeny	3
Single Jersey Circular	Mayer & Cie	Germany	8
Single Jersey Circular	Sanda	Taiwan	2
Interlock Circular	Mayer & Cie	Germany	2
Rib-Interlock Circular	Mayer & Cie	Germany	1
Rib Circular	Mayer & Cie	Germany	2
Auto Stripe Circular	Pai Lung	Taiwan	1
Fleece Circular	Lisky	Taiwan	1
Total Circular Knitting Machines			19
Flat Bed	Matsuya	Japan	4
Flat Bed	Flying Horse	Taiwan	2
Flat Bed	Around Star	Taiwan	2
Total Flat/Collar Knitting Machines			8

Machine Type	Manufacturer	Country of Origin	Qty
Yarn Count Machine	MAG	India	1
Electronic Twist Tester	MAG	India	1
Yarn Appearance Board Winder	MAG	India	1
ASTM	MB	China	3
Fabric Inspector	UZU	Thailand	1
Total Knitting Lab Equipment			7

Dyeing Unit

The dyeing unit spans approximately 8,500 sq. ft., with dedicated spaces for batch preparation and wet fabric storage. State-of-the-art high-temperature dyeing machines operate daily, delivering a capacity of 14 tons/day. The unit is thoughtfully designed with a 24 ft. high shed, ample windows, and a high-performance air exhaust system to effectively manage heat and maintain an optimal working environment.

Machine Type	Manufacturer	Country	MC (Kg/Batch)
High Temperature, Pressure & Eco Flow Dyeing Machine	Dilmenler	Turkey	1500
High Temperature, Pressure & Eco Flow Dyeing Machine	Dilmenler	Turkey	1000
High Temperature, Pressure & Eco Flow Dyeing Machine	Dilmenler	Turkey	800
High Temperature, Pressure & Eco Flow Dyeing Machine	Dilmenler	Turkey	600
High Temperature, Pressure & Eco Flow Dyeing Machine	Fongs/Then	Germany	500
High Temperature, Pressure & Eco Flow Dyeing Machine	Dilmenler	Turkey	450
High Temperature, Pressure & Eco Flow Dyeing Machine	Dilmenler	Turkey	400
High Temperature, Pressure & Eco Flow Dyeing Machine	Dilmenler	Turkey	200
High Temperature, Pressure & Eco Flow Dyeing Machine	Dilmenler	Turkey	100
High Temperature, Pressure & Eco Flow Dyeing Machine	Dilmenler	Turkey	50
Sample Dyeing Machine	Suntex	Hong Kong	30
Sample Dyeing Machine	Suntex	Turkey	30
Sample Dyeing Machine	Dilmenler	Turkey	15
Sample Dyeing Machine	Dilmenler	Turkey	15
Sample Dyeing Machine	Dilmenler	Turkey	15
Sample Dyeing Machine	Suntex	China	20
Sample Dyeing Machine	Suntex	China	10

Dyeing Finishing Section

Covering approximately 14,000 sq. ft., our dyeing and finishing unit includes dedicated spaces for batch preparation and wet fabric storage. The unit operates advanced finishing machines, achieving a daily capacity of 10 tons. Efficient heat dissipation is ensured by maintaining a shed height of 35 feet, with ample windows and air exhaust systems in place.

Machine Type	Manufacturer	Country	MC (Kg/Batch)
Balloon Squeezer	Mersan	Turkey	6,000
Balloon Squeezer / Slitting Machine	Dilmenler	Turkey	10,000
Fabric Turning Machine	Daroi-tex	Italy	4,000
Tube Compactor	Tube tex	U.S.A	6,500
Fabric Dryer Machine	Alea	Italy	3,500
Tumble Dryer	Peacock	Taiwan	700
Open Width Compactor	Lafer	Italy	12,000
Stenter Machine	Bruckner	Germany	10,000
Fabric Inspection Machine	UZU	Thailand	4,000

Knit Garments Unit

Our knit garments unit spans approximately 78,500 sq. ft. across five floors, boasting a monthly production capacity of over 2 million knit garments. Equipped with high-capacity machines from Japan, China, Turkey, and beyond, the unit is strategically organized into fabric cutting, sewing, garment finishing, and inspection areas, along with dedicated office space. Intelligent ventilation systems ensure optimal working conditions throughout the facility.

Machine Type	Manufacturer	Country	Qty
Plain Machine (Auto Trimming)	Juki	Japan	283
Plain Machine (Auto Trimming)	Brothers	Japan	20
Plain Machine	Juki	Japan	52
Overlock Machine (4 Thread)	Juki	Japan	204
Overlock Machine (4 Thread)	Pegasus	Japan	43
Flatlock Cylinder Bed Machine	Juki	Japan	75
Flatlock Cylinder Bed Machine	Pegasus	Japan	19
Flatlock Flat Bed Machine	Juki	Japan	25
Flatlock Flat Bed Machine	Pegasus	Japan	10
Button Hole Machine	Juki	Japan	17
Button Stitch Machine	Juki	Japan	14
Button Stitch Machine	Juki	Japan	9
PMD Machine	Kansai	Japan	5
Feed off the arm Machine	Juki	Japan	8
Zigzag Stitch Machine	Singer	China	2
Picoting Machine	Kansai	Japan	6
Rib Cutter Machine	Zoje	China	11
Snap Button Attach Machine	Max	China	14
Fabric Cutting Machine	KM	Japan	13
Thread Trimmer Machine	Grand	China	6
Metal Detector	Lock	-	1
Reconing Machine	Zoje	China	2
Vacuum Iron Table	Nisho	Japan	15
Vacuum Iron Table	Oshima	Japan	39
Fabric Relax Machine	Empenzo	Turkey	1
Thread Sucking Machine	Nisho	Japan	3

Woven Garments Unit

Spanning approximately 22,300 sq. ft. across 12 floors in two buildings, our woven garments unit has a monthly production capacity exceeding 0.40 million garments. Outfitted with high-capacity machines from China, Taiwan, Singapore, Japan, and other leading countries, the unit is smartly organized into sections for cutting, sewing and finishing, and finished goods inspection, with dedicated office spaces integrated throughout. The facility is designed with intelligent ventilation systems, ensuring an optimal working environment for all processes.

Machine Type	Manufacturer	Country	Qty
Plain Machine (Auto Trimming)	Juki	Japan	363
Plain Machine	Juki	Japan	8
Vertical Machine	Juki	Japan	38
Overlock Machine (5 Thread)	Juki	Japan	34
Button Hole Machine	Juki	Japan	35
Button Stitch Machine	Juki	Japan	19
PMD Machine	Kansai	Japan	12
Feed Off the Arm Machine	Juki	Japan	29
2 Needle Chain Stitch Machine	Juki	Japan	16
2 Needle Chain Stitch Machine	Juki	Japan	20
2 Needle Chain Stitch Machine	Juki	Japan	12
Fabric Cutting Machine	KM	Japan	5
Band Knife Cutting Machine	Eastman	USA	1
Band Knife Cutting Machine	Oshima	China/Taiwan	1
Band Knife Cutting Machine	Ngai Shing	China	1
Metal Detector	Lock	-	1
Metal Detector	Yock	-	1
Reconing Machine	Zoje	China	2
Vacuum Iron Table	Nisho	Taiwan	20
Vacuum Iron Table	Ngai Shing	China	15
Vacuum Iron Table	Veit	-	15
Fabric De-Humidifier	Bry-Air	India	2
Thread Sucking Machine	Ngai Shing	China	1
Thread Sucking Machine	Shengtian	China	1
Fabric Inspection Machine	UZU	-	1
Re-Roller Machine	Ngai Shing	China	1
Interlining Cutting Machine	Ngai Shing	China	1
Neck Press Machine	Ngai Shing	China	3
Collar Turning Machine	Ngai Shing	China	5
Collar Forming Machine	Ngai Shing	China	11
Collar Bottom Cutting Machine	Ngai Shing	China	11
Collar Bottom Cutting Machine	Ngai Shing	China	8
Collar Bottom Cutting Machine	NISSIN	Singapore	1
Cuff Forming Machine	Ngai Shing	China	6
Armhole Press Machine	Ngai Shing	China	2
Armhole Press Machine	Veit	Germany	1
Side Seam Press Machine	Ngai Shing	China	1
Collar and Neck press machine	Ngai Shing	China	1
Rolling Fusing Machine	Ngai Shing	China	1
Top Center Fusing Machine	Ngai Shing	China	1
Plucket Fusing Machine	Ngai Shing	China	2
Collar Forming Machine	Ngai Shing	China	2
Cuff Forming Machine	Ngai Shing	China	1
Collar Bottom Cutting	Ngai Shing	China	2
Coller Forming Machine	Ngai Shing	China	1
Rolling Fusing Machine	Ngai Shing	China	1
Top Center Fusing Machine	Ngai Shing	China	1
Plucket Fusing Machine	Ngai Shing	China	2
Collar Forming Machine	Ngai Shing	China	2
Cuff Forming Machine	Ngai Shing	China	1
Collar Bottom Cutting	Ngai Shing	China	2
Coller Forming Machine	Ngai Shing	China	1
Rolling Fusing Machine	Ngai Shing	China	1
Cuff Forming Machine	Ngai Shing	China	2
Plucket Fusing Machine	Ngai Shing	China	1
Collar Forming Machine	Ngai Shing	China	2
Collar Bottom Cutting Machine	Ngai Shing	China	3
Collar and Cuff Fusing Machine	Veit	Germany	1
Collar and Cuff Fusing Machine	Reliant	USA	1

Print Unit

The print units, spanning 6,000 sq. ft. within the production area, are meticulously arranged to enhance both printing accuracy and efficiency. Equipped with advanced machinery such as Belt Dryer Machines, Table Top Run Dryers, Exposers, Print Tables, and Mesh Tables, our facility ensures precise prints and optimized drying processes, reflecting our commitment to high-quality production standards.

Machine Type	Manufacturer	Country	QTY
Belt Dryer Machine	TDX	China	1
Table Top Run Dryer	TDX	China	4
Exposer	TDX	China	1
Print Table	OAK	China	1
Mesh Table	OAK	China	1

Curing Unit

Garment Dry Curing Room

We operate two dedicated garment dry curing rooms, spanning 357 sq. ft. and 437 sq. ft., with impressive capacities of 2,420 and 3,000 pieces per batch, respectively. Each room is equipped with state-of-the-art desiccant rotor dehumidifiers, ensuring precise moisture control throughout the curing process.

Additionally, our advanced racking system is meticulously designed to ensure that each garment dries thoroughly, effectively preventing mold accumulation, particularly during the rainy season or extended shipping periods.

Lab Unit

Our laboratory, strategically positioned between the dyeing and finishing units on the first floor, is designed with a see-through provision to ensure transparency and ease of monitoring. This state-of-the-art facility is equipped with industry-leading dye and fabric testing units, enabling us to deliver detailed and reliable results.

Operated by skilled professionals, our lab meets stringent customer stipulations and quality standards effortlessly. Our advanced equipment from renowned brands ensure that our testing processes are accurate, reliable, and in line with global standards.

Machine Type	Manufacturer	Country	QTY
HT Lab Dyeing Machine	Mathews	China	2
Shrinkage Test Template -	-	China	1
Fabric Dryer Machine	Bosch	Turkey	1
Fabric Dryer Machine	Whirlpool	USA	1
Fabric Washing Machine	Samsung	South Korea	1
Fabric Washing Machine	Samsung	South Korea	1
Color Fastness Tester	Innolab	India	1
Color Matching Light Box	Verivide	UK	2
Crock Meter	UTS	China	1