The production process is fully vertically integrated and consists of several manufacturing operations which cover the full spectrum of textiles and clothing production, i.e. yarn spinning, fabric knitting, fabric dyeing, cutting, assembly and finishing of garments.
Controlling each of the manufacturing processes has enabled Vic Bay to control its destiny in critical areas such as product quality, product availability and costs.
Vic Bay's state of the art spinning mill where cotton yarn of various tex counts are spun. This spinning plant operates 24 hours per day, seven days per week to meet the demand for Vic Bay's products.Our 100% cotton yarn is subjected to stringent tests to ensure the highest quality open-end yarn.
Cotton bales are laid out side by side beneath an automated opening machine arm which plucks off cotton fibre and feeds to a storage hopper.
Cotton to sliver
Vic Bay's state of the art machinery ensures that all impurities are removed from the cotton lint and sliver process before being spun into yarn. Temperature and humidity are strictly controlled during this stage of production.
Sliver to yarn
During the spinning process the sliver is separated into its individual fibres and is subsequently reassembled into a yarn strong enough for knitting.
The groups knitting factory is where single jersey fabric is knitted in body size tubular form allowing for seamless-side products. We also produce wide width fabric for our golf, junior and winter product ranges as well as special customer orders.
We produce cotton fabrics of various qualities, which are available in a wide range of colours. Our fabric is used in a variety of products and in a number of well-known brands and trade marks.
The spun yarn is fed into knitting machines which knit the yarn into tubular webs. Tubular fabric allows the main body of the garment to be made without cutting, stitching or joining – ensuring better shape retention.
Vic Bay's dye house and finishing plant is where fabric is dyed to international colour fastness and performance benchmarks to ensure stability. Using the latest dye machine technology, our knitted fabric is automatically loaded into the machine where it rotates through the dyeing process. Fabric is conditioned by adding a softener and is then processed through the calendar machine to the required width and dried.
Our state-of-the-art Bierrebi automatic cutting machines are used to ensure fast and accurate cutting of garments. The highly advanced automated template cutting ensures maximum precision, productivity and cost efficiency together with minimum fabric wastage.
Assembling the garment - At our garment assembly factories, the cut panels are sewn together into a wide range of t-shirts, polo's and sweatshirt styles by teams of qualified machinists with a high emphasis on quality control.
At our assembly operations in South Africa and Lesotho, garments are manufactured according to the highest standards.