OCTOBER4128 (BD) LTD.
One route through the building, in one direction: material in at one end, inspected at every stage, packed at the other.
PLANNED — UNDER CONSTRUCTION
The plant is laid out so material travels in a single direction. Incoming fabric never crosses finished cartons, inspection happens where a fault can still be corrected, and every stage sits next to the one before it.
STAGE 01 TO 05
Fabric and materials come off the truck straight into a temperature- and humidity-controlled store.
A separate, conditioned cutting room with automated tables, so the panel that reaches the line is the panel the pattern intended.
Eighty lines across the production floors, each laid out to the same plan so a style can be moved between lines without relearning the balance.
A controlled room where garments are conditioned before they are packed, which matters for insulated and laminated products more than for anything else we make.
Cleared garments are folded or hung, packed to the buyer's own instruction, and held in a finished-goods store until the container is loaded.
THE WHOLE BUILDING
Not only the warehouse. Every production floor, the cutting room, the dry room and the finished-goods store are held within a set temperature and humidity range and monitored continuously.
STAGE 01 — INTAKE
Fabric and materials come off the truck straight into a temperature- and humidity-controlled store. Material that has been held at a stable moisture content behaves the same on the cutting table in August as it does in January.
Temperature and relative humidity are held within a set range and logged continuously, rather than left to the weather. This is the single cheapest way to prevent shrinkage and dimensional problems that would otherwise surface after cutting.
Every roll is checked and recorded on arrival — shade, width, length and a four-point fabric inspection — before it is accepted into stock.
Rolls are racked and barcoded rather than piled on the floor, so stock rotates oldest-first and nothing is crushed, creased or mislaid.
Rolls are grouped by shade band and dye lot, so no garment is ever assembled from two lots that will not match under a buyer's lightbox.
Fabric is relaxed in controlled conditions before it is spread. Most dimensional faults are prevented here rather than discovered later.
The store opens directly onto the cutting room, so material moves in a single direction and never crosses a finished-goods route.
STAGE 02 — CUTTING
A separate, conditioned cutting room with automated tables, so the panel that reaches the line is the panel the pattern intended.
Computer-controlled cutting rather than band-knife work, which holds tolerance across the whole lay instead of only the top plies — the difference technical outerwear panels depend on.
Markers are made and checked digitally, so consumption is known before a single metre is spread and the same marker is reproducible on a repeat order.
A dedicated station for precise pattern marking and template preparation, so notches, pocket positions and welt placements are set from a template rather than judged by eye.
Spreading is done under the same conditions the fabric was relaxed in, with tension controlled so panels do not spring back once they are released.
Cut parts are bundled, ticketed and tracked by lay and lot, so a panel can be traced back to its roll if a problem appears downstream.
Panels are audited against the pattern before they are issued to a line. A fault caught on the cutting table costs a panel; the same fault caught after assembly costs a garment.
STAGE 03 — ASSEMBLY
Eighty lines across the production floors, each laid out to the same plan so a style can be moved between lines without relearning the balance.
Every line is built to the same arrangement — feeding, sewing stations, in-line inspection, ironing and finishing in a fixed order. A buyer auditing one line has effectively audited them all.
Shell and lining inspection tables sit inside the line rather than at the end of it, so a fault is found while the seam can still be opened.
Adjustable chairs, task lighting and correct table heights. Back, neck and wrist strain is the main cause of lost output on a long run.
Aisles and gangways are marked and kept clear, which keeps material moving and keeps the floor compliant on a fire-safety audit.
Continuous linear lighting over each line rather than point fixtures, so an operator is not inspecting dark stitching against a bright table.
The sewing floors are climate controlled like the rest of the building — a comfort measure, and the reason coated and laminated fabrics handle consistently through the day.
THE SAME PLAN, EIGHTY TIMES
Cut panels are fed in at one end and leave the other as a finished garment. Two rows of sewing workstations face a central transport rail; the inspection and finishing stations sit at fixed positions along it. Because every line is built to this same arrangement, a style can be moved between lines without rebalancing it, and a buyer who has audited one line has effectively audited all eighty.
Schematic of one line — scroll sideways to see it all.
The repeating unit of the line. Adjustable seating, task lighting and correct table height at every position, arranged in two facing rows so work passes across the rail rather than around the floor.
Two of them, inside the line: shell inspection early, lining inspection further along. Stitching, measurements, appearance and workmanship are checked while the seam can still be opened.
A wide table at the end of the run where the garment is brought to its final state — trims checked, loose threads removed, the piece presented flat — before it leaves the line for final inspection.
An automated station alongside the line for precise pattern marking and template preparation, so repeated details are set from a template and come out identical on every unit of the order.
STAGE 04 — CONDITIONING
A controlled room where garments are conditioned before they are packed, which matters for insulated and laminated products more than for anything else we make.
A room held at a set temperature and low humidity, so garments are dried evenly rather than left to the ambient air of the floor.
Insulated garments are given time to recover their loft after handling and pressing, so what the buyer opens is what the buyer specified.
A garment packed with moisture in it is a garment that arrives with mildew after six weeks at sea. This is the step that prevents it.
Not every style passes through. Insulated, laminated and seam-sealed products do; a simple woven shell may not.
Temperature and humidity in the room are recorded, so conditioning is a documented step rather than an assumption.
Placed on the route so conditioning never becomes a detour that production is tempted to skip.
STAGE 05 — PACKING & DISPATCH
Cleared garments are folded or hung, packed to the buyer's own instruction, and held in a finished-goods store until the container is loaded.
Folding, hanging, poly-bagging, ratio packing and assortment exactly as that buyer specifies, because a correct garment in a wrong carton is still a claim.
Shipping marks, barcodes and carton content labels applied and verified against the packing list.
A proportion of cartons is opened and audited after packing, which is where ratio and assortment errors are actually caught.
Packed cartons are held in a conditioned store, not on the production floor, so the last stage of the journey is as controlled as the first.
Dispatch is on a separate route from goods-in, so incoming material and finished cartons never cross.
Containers are loaded directly from the finished-goods store with documentation checked at the door.
RESOURCES ON SITE
A climate-controlled building uses energy and a garment plant uses water. Both are designed for from the start rather than retrofitted, because the roof area and the drainage runs have to be planned before the structure goes up.
GROUND + FIVE FLOORS, ROOF
Presentation plans from the architectural drawing set. Select a plan to enlarge it.
SUPPORT BUILDING
A separate building on the northern edge of the site, next to the wellness center.
See it on the site planA plant is a building until it is staffed. The same site plan carries a wellness center, doctor chamber, child care, a prayer hall, a library and a sports ground.
