Working Phases

The organization model

Since many years, "Orchidea Blu" is able to realize all the phases for the realization of the products that are tailoring, cutting, seam and package. Some operations, usually related to sewing, are sometimes garanted to other laboartories that are part of the district of which the company is leader because organizes, manages and controls all the phases and oversee to all the activies that precede and follow the packaging.

The main manifacturing steps that "Orchidea Blu" takes care in its large production cycle are:

CREATION

OPERATION BEFORE PACKAGING

PACKAGING

FINISHING

Creation Area

Creatiionincludes realization and development of models which concerns the designer's sketches interpretation and iots translation in precise geometrical patterns. It's possible to create new patterns or modify pre-existent patterns already stored in computer memory.
Currently, an external partner supports "Orchidea Blu" for the realization of the purely digital phase which gives the guidelines for pattern realization in order to simplify and, at the same time, to make more accurate the following phases of cutting and packaging.

The creation phase begins with elaboration, development and printing of graphics for the garments cutting using Plotter (Lectra Alys 20+)

Operation before packaging

The second phase include all the operations before packaging, first of all development of sizes and placement. Development of sizes is copy of the prototype in each of the sizes in which it has to be realized. The purpose of the placement is to determine how it should be cutted, in order to obtain the garment parts using the less possible tissue consumation.

After that, there is the cross-lapping phase that is an operation of multiple layers of tissue superimposing which together form the mattress.

Cross-lapping and mattress cutting allow the simultaneous cutting of many parts riducing the time and ensuring the dimensional constancy of cutted parts. The crossing-lapping machines use is important because allows to reduce time and costs of lapping and lying.

In this sense, "Orchidea Blu" is providing for obtain another automatic spreader machin increasing the machine supply and the number of items to labels on tissue and the cut made with a semi-automatic cutting system. 

Packaging Area 

At this point, we are in the real assembly phase. The various stages of construction of products are done by sewing machines like linears, overlockers, rebeating, button hole maker, zig-zagers, invisible fringe makers, 2-3 cover needelers, collar cutters and attachers, arriving to the latest realization of the garment that still needs other treatments.

Finishing

The finish is the last of the processing steps and it consists in washing and eventually dyeing of garments. In fact, the company uses washers and dryers for the garment washing, usually for those ones that doesn’t need to be dyed because most of the production is made using white tissues that are dyed in dye-works only after have been sewed. The company is helped by northen Italy partners, experts in dyes in tissue sector.

Obviously, Orchidea Blu takes care of all the work of this phase, from preparing (some tissues needa particular process before been dyed) to shipment using couriers, garment sorting and dye works.

This is followed by quality control in order to checking flaws that may compromise the final result of the work. This is made through the use of luminous mannequines that allows the detection of rips, flaws or sewing mistakes before the finishing of the clothes. When an operator finds out defective pieces, he sends them to the control station to be repared or excluded if the reparation is not possible or is not affordable.

In the end, it is necessary to submit the product to some operation that make it suitable for sale and cured in presentation by ironing, bending and packaging.

Ironing is made using boards and standard irons, but also a mannequin equipped with an aeration system that blow up the garment during steam ironing and a rectangural ironing boards for T-shirt ironing in particular.

Folding and packing are realized on two different tables where there are containers in which are envelopes and flimsy paper supplied by companies (brands) and after this step the products are finished and ready to be placed on market, after the arrangement in the appropriate boxes and the shipment to the buyer company that will take care of distribution to stores all over the world.