Infrastructure
Dye house

1) Processing Unit
The Dyeing Division Is Equipped with Soft-flow And Ht-hp Vessels from Fong's And Tong Geng Dyeing Machines, Finished with Santex Squeezer and Ruckh Calator Drier from Germany. Bruckner Stentering with 8 Chambers from Germany and Corino Slit Open Machine from Italy. The Unit has 20 Tons Capacity of Fabric Dyeing per day.

For Fabric Stretching (Balloon Padding), RCG is using a special machine from Santex Santa Stretch Plus of Switzerland with Squeezing and Wet Stretching. The Dryer Division is equipped with the latest Relax Dryer from Calator Ruchk of Germany with 3 Chambers and a Wet Stretching Facility.

2) Stentering machine
3) Water treatement plant
To Retain an Eco Friendly Nature, Installation of Reverse Osmosis Plant for water treatment have been undertaken with a capacity Of 10 Lakh Litres/day, by which the status of "Zero" effluent discharge unit have been achieved.


Knitting Division

1) Knitting machines
The Knitting Division Has 84 Circular Knitting Machines of Mayer & CIE from Germany, and Orizio from Italy and Pailung from Taiwan. It also has flat Knitting Machines of Kauo Heng-Taiwan, with a capacity to produce 10 Tons of fabric per day.


Wet process
1) Compacting (Pre-Shrinking Process)
Consists of Tube-tex, USA Tubular and Open Width Compacting Machines -4 Nos. and Monti Of Italy, Felt Compacting Machines For Mercerized Fabrics. Also Tong Geng Chamber Heat Setting Machines for Lycra and Polyester Fabrics which can handle fabrics up to a width of 48 Inches. The capacity of the Compacting Department is 15 Tons of fabric per day.


Garmenting Division
1) Knits Factory Building:
i. Cutting
The completely integrated facilities is topped by our garmenting division with skilled pattern masters, cutting masters, tailors and supporting workmen who are well trained. The product specialization gives an excellent finish to the garments we make. The entire production wing is housed under one roof with scientific work systems and quality control systems.

ii. Punch Cutting
Besides, our Cutting Division is also been equipped with the Bierbi Cutting Machine from Italy, especially For Tubular and Infant products. Also equipped with Band Knife Cutting Machine.

iii. Sewing Unit
Our Sewing Division is equipped With 2100 Machines collectively imported from Peqasus, Yamato, Durkopp Adler & Siruba.

To produce following pieces sewing capacity/day is:
FOR T-SHIRTS                           20,000 PCS.
FOR JACKETS                             2,000 PCS.
FOR UNDER GARMENTS          1,09,000 PCS.

2) Woven Factory:
Classic Polo’s woven division has high-end machines which are all imported from Durkopp Adler, Germany and Pfaff, Germany. They are fully computerized and all lock stitch machines have automatic under-bed thread trimmers. Classic Polo’s unit which can produce 2000 trousers per day and 1000 shirts per day has been set with the training of German consultants.

i. Wing Pocket Attaching machine
Wing pocket Attaching machine attaches the pocketing cloth to the front panel of trousers - be it a front opening pocket or side opening pocket. It also makes the notches at the correct place of the front panel which ensures correct size of pocket opening and also helps to avoid an up and down position between the right side pocket and the left side pocket - a chronic problem that usually happened when done manually. The front or side pockets, being present in the “A-Zone” of the garment can make or mark the aesthetic look of the trouser and hence the wing pocket attaching machine is of paramount importance in the connection of a good quality trouser. Besides the above, this machine gives 4 times more output compared to the manual operation and thus brings down the cost of production.

ii. Automatic Side Surging Machine
Automatic Side Surging Machine stitches the sides of the trouser with ease and perfection the seams are need and the dimensions are uniform, maintaining a perfect fit enhancing the productivity and thus bringing down the cost.

iii. Automatic Pleat and Dart Making machine
Automatic Pleat and Dart Making machine creates the front pleat and back dart automatically. It ensures precision of placements and dimensions and perfect uniformity will be maintain in the entire lot of production.

iv. Computerized Eyelet Hole Machine
Computerized Eyelet Hole machine makes eye let holes with different combinations of size, design and shape.

v. Computerized Bar Tracking Machine
Computerized Bar tracking machine is available in our factory are fully programmable and help determine the size, width, shape and density of the bar track stitches. Apart from this, these machines also have the sequential operation feature that helps the operator to make different size/shape stitches in the same machine in one stitching. Thus material handling is made easier and saves a lot of time and also provides possible staining of the garment due to multiple handling of the garment and movement between work stations.

vi. Leggers and Toppers
The trousers, especially the 100% cotton trousers and more particularly the washed pieces will have inherent dead creases that are formed during the manufacturing process & drying process. It becomes difficult to remove all these creases and wrinkles in the conventional method of manual iron processing. These creases and the wrinkles need forced streaming and suction coupled with pneumatically controlled controlled pressing. It is difficult and impossible to reach certain areas of the top side of the trousers like the front fly zone, just below the waist band and hip are with the manually handled ironed boxes and sometimes, if attempted with yield adverse results like creation of new creases and puckering or sometimes reshapes the garments as well. Therefore leggers and toppers give good ironing results by removing all the dead creases and wrinkles and also eliminate the puckering along the stitch lines.

vii. Permanent Crease Lines
The latest technology from Clantex, U.K., that gives permanent crease lines to the trousers enhances its aesthetic appearance and also enables easy care of the garments.

viii. Washing
There are different types of garment washers done in our factory- silicon wash, softener wash, enzyme wash, acid wash, golf ball wash, etc. their washing capacity is 2,000 pieces of trousers and 1,500 pieces of shirts per day.

ix. Wrinkle Free Finish
We have adopted German Technology and the washing and finishing are done in collaboration with M/s Weishi, China. Our employees have been well-trained by the chief technicians of Weishi and the technical knowledge is being constantly upgraded by their training.

x. Oven
The trousers washed with wrinkle-free chemicals are taken to the hydro extractor machines and the hydro extracted trousers, with about 20 % moisture content is pressed in leggers and toppers to remove the creases and wrinkles formed during confectioning /washing and then are baked in the Oven at the required temperature and time. The baking is a curing process and the bone dried trousers are taken out of the oven and cooled at the room temperature for a while.

xi. Cooling Chamber
The bone dried stick cooling which allows the trousers to regain the moisture quickly and more importantly are weathered well to gain a superb hand feel !


VALUE ADDITION ON GARMENTS

1) Chest printing
The Printing Division is also been equipped with Automatic Chest Printing, Machine from MHM, Turkey and M & R U.S.A for Chest Prints.

2) Fabric Printing
The Printing Division is also been equipped with Automatic Chest Printing, Machine from MHM, Turkey and M & R U.S.A for Chest Prints.

3) Embroidery
The Embroidery Division is equipped with the latest machines from Tajima – Japan (20 Head - 2nos. And 8 Head – 1 No.). These machines take care of all the embroidery requirements.

Wind Mills
RCG has installed 5 Windmills of total 3.75 MW capacity taking care of the entire power requirements of the group at cost of Rs. 150 million. These 5 machines are the latest from Neg-Micon of Denmark. By generating this green power, RCG is saving gallons of fuel and metric tones of coal for the nation, with equivalent avoidance of harmful carbon emission into the biosphere.