Production
Cotton
Orta Anadolu uses top quality cotton having high strength and fibre length both from internal and external sources in order to produce high quality special denim and flat fabrics.
Cotton purchasing as bulk portions avoids fluctuation at fabric quality. Each and every bale's fiber properties are tested and categorised. This classified data is analysed by the help of unique software in order to make continuous and constant cotton feeding.
Yarn Spinning
Yarn is one of the fundamental components for quality and innovation in denim production.
Thanks to continuously renewed, up-to-date ring yarn spinning machinery in Orta Anadolu, best technology is used. Being a member of star team with its giant and reputable brand labels, each machinery has its last version. On-line data flow and analysis systems are used in order to follow up quality and efficiency of machinery.
Endless investments have been going on for innovation and production of different yarn effects and all Ring spinning machines are equipped with special "Amsler effect yarn" apparatus. (A very special spinning machine)
Moreover, "Core yarn" production equipment for lycra content stretch fabrics is another asset in yarn production. In order to process yarn according to demands of fabric designers and to get utmost benefit of this superb yarn machinery, a Swedish spinning engineer who is among the world\'s experts in this area is supervising the "Amsler".
Indigo
Now it is the time for yarn to get legendary colour of indigo.
The rope-dyeing process which is known to be the best system in the world is being operated by giant machinery of "Morrison". Thanks to operation principle of these machines "side-to-side" shade difference is not seen on "Ordenim" fabrics. Besides, these machines have the capability of producing the darkest indigo denim in the world.
Indigo dyeing process is on-line controlled at each machine over 300 checkpoints.
Weaving
"Weaving" is the stage where denim fabric begins to take form...
Specially selected "Sulzer" projectile, "Dornier" Air-Jet and "Dornier" Rapier weaving machines are placed on a double-storeyed hall designed for denim fabric weaving.
Fabric woven at upper storey has been winded up on big rolls as grey fabric at ground floor. Production planning and performance ratings are run with special software programs.
Besides, there have been 4 single-width sample weaving machines for product development and training purposes.
Finishing
Finishing is the last stage for fabric production. Orta Anadolu is continuously doing research & development studies and making investments in order to get innovative, new and different aspects on Ordenim, Denimperial, Denimus and Orcotton (non-denim) fabrics.
The denim-finish line that is established only for denim fabric enables "Orta Anadolu" to perform all finishing operations, including singeing and skew-movement adjustments. The last process of this line is "Sanforising" where shrinkage is adjusted.
Quality Control
Apart from all on-line quality control stages during production, the final quality control system is applied on all finished fabrics with utmost detail and with the aid of updated technology. Fabric is tested and evaluated at 3 different stages after finished:
Physical control
Finished fabric is subjected to following tests referring international AATCC and ASTM test methods: Unwashed tests; Width, weight, stiffness, elongation, crocking. Washed tests; Width, weight, Shrinkage, movement after skewing, tear and tensile strength, flex cycle abrasion.
Visual control
After physical testings, 100% of fabric produced is inspected. All defects are marked and flagged using 4-point system, defect map is created thanks to advanced software that has been particularly developed by Orta experts and rolls are packaged with durable material to become ready for shipment.
Shade control
Here starts the most difficult evaluation phase for the fabric. A visual assesment of experienced staff performed with a computer-aided shade evaluation is carried out in order to ensure consistency and continuity of shade.
Once fabric has successfully passed these three stages of control, fabric passport is issued and recorded.
Product Development
"Ordenim", "Denimperial" and "Orcotton" brands are born in product development department. We have number of denim and fabric gurus thinking and creating for Orta Anadolu.
Orta Anadolu has been able to accomplish the most difficult aspect in denim production many times which is "Creativity". Developments that require explicit knowledge as well as technology are famed by their names in denim fabric literature. (Flat Optics, Homespun, Crunch, Fillmore, Panhandle, Fossil, BluLux)
As being the leading innovative company of each and every era, Orta Anadolu with its ability to integrate the creativity with technology is the approved supplier of major Jeanswear and Sportswear brands.