Manufacturing Overview
Sak Sportswear operates an 8,500-square-meter apparel production facility specialized in technical activewear, yoga wear, and performance sportswear. Our operations integrate design development, automated CNC cutting, specialized digital/screen printing, multi-needle stitching, and rigorous quality inspection under one roof. Operating under ISO 9001 quality management standards and certified by OEKO-TEX Standard 100 and BSCI / WRAP social compliance audits, we manage production scaling from low-MOQ pilot runs to large-scale commercial volume, maintaining consistent technical standards for global apparel brands and independent labels.
Manufacturing Capabilities
Our facility utilizes specialized machinery and standardized production lines tailored strictly for high-stretch, synthetic, and blended performance fabrics.
Production Facility Area: 8,500 square meters.
Monthly Capacity: 180,000 to 250,000 pieces (depending on garment complexity).
Core Machinery:
4-needle 6-thread flatlock sewing machines (Kansai Special / Pegasus) for seamless-feel athletic seams.
Computerized automatic fabric spreading and CNC cutting tables (Lectra / Gerber).
High-speed sublimation printers and pneumatic heat transfer presses.
Automatic pattern sewing machines for precise bartacking and structural reinforcement.
Handled Fabrics: Nylon-spandex blends, polyester-elastane knits, merino wool performance blends, recycled polyester (RPET), and bonded waterproof membranes.
Sportswear Production Process
Our standard manufacturing workflow follows a traceable sequence designed to eliminate variance between pre-production samples and bulk shipments.
Tech Pack Review -> Fabric & Trim Sourcing -> Pattern Grading -> Sampling & Approval -> CNC Cutting -> Printing/Embroidery -> Garment Assembly -> In-Process QC -> Finishing & Needle Detection -> Bulk Packaging & Shipment
Fabric Cutting
Dimensional stability in high-stretch sportswear begins at the cutting table. We use computerized cutting systems to minimize human error and fabric distortion.
Relaxation Process
Rolled technical fabrics undergo a mandatory 24-hour relaxation period in a temperature- and humidity-controlled room prior to cutting to eliminate residual tension and prevent post-wash shrinkage.
Marker Making
Computer-aided design (CAD) nesting software optimizes fabric utilization while aligning directional prints and stretch grain lines precisely with garment stress points.
Cutting Precision
CNC multi-ply cutting machines maintain a cutting tolerance of within plus-or-minus 0.5 mm, ensuring identical panel symmetry across bulk runs.
Printing & Embroidery
Activewear graphics require durability against sweat, UV exposure, and mechanical stretch. We match print and embellishment methods directly to the fabric composition.
Sublimation Printing
High-resolution digital transfer printing using eco-friendly, OEKO-TEX certified Italian transfer inks, ensuring 100% ink penetration into polyester fibers with zero hand-feel and zero cracking under stretch.
Screen Printing
Utilizes specialized silicone and high-density water-based inks designed to bond with elastane-blended fabrics without peeling during cyclic elongation.
Heat Transfer & Reflective Logos
Industrial application of certified 3M reflective films for night-running safety and silicone heat seals for tagless neck labels.
Multi-Head Embroidery
Tajima computerized embroidery machines equipped with soluble backing for delicate performance meshes, preventing puckering along stitch lines.
Sewing & Garment Assembly
Activewear construction requires specialized stitch formations capable of withstanding high dynamic tension without seam failure.
Stitch Engineering
We enforce strict Stitch Per Inch (SPI) counts, ranging from 12 to 14 SPI for structural seams, to balance seam strength with fabric elasticity.
Flatlock Construction
4-needle 6-thread flatlock machines create flat, low-profile seams that eliminate chafing against skin during high-intensity motion.
Reinforcement
Bartacking is applied automatically to high-stress junctures, including pocket corners, waistband joins, and zipper ends.
Operator Specialization
Assembly lines are segregated by garment type (e.g., seamless-look bonded waistbands for leggings vs. engineered raglan sleeves for compression shirts), ensuring technician familiarity and consistent output quality.
Finishing & Inspection
Garments undergo a multi-stage finishing and auditing sequence before final cartoning.
Thread Trimming
Automated and manual trimming removes all loose thread ends exceeding 2 mm.
Ironing & Shaping
Pneumatic steam forms shape garments to retail-ready dimensions without scorching synthetic fibers.
Metal Detection
Every single garment passes through an industrial conveyor metal detector to ensure no broken sewing needles or metal fragments remain embedded in the fabric.
AQL 2.5 Standard
Final inspections follow the ISO 2859-1 (ANSI/ASQC Z1.4) Sampling Procedures for Inspection by Attributes, assessing critical, major, and minor defects before sign-off. Inspection reports are archived and accessible for client audit reviews.
Sampling & Product Development
We translate client tech packs, sketches, or physical reference samples into production-ready prototypes.
Tech Pack Audit
Our engineering team reviews tech packs for technical feasibility, recommending adjustments to graded specs, seam allowances, or fabric weights if potential structural weaknesses are identified.
Pattern Engineering
Digital grading is executed using specialized apparel CAD software across full size ranges (e.g., XS to 3XL).
Sample Lead Time
Proto samples are completed within 5 to 7 working days upon fabric and trim confirmation; fit/PP (Pre-Production) samples are delivered within 10 to 12 working days.
Production Management
Operational transparency and schedule adherence are managed through digital tracking systems.
Critical Path Method (CPM)
Every order is assigned a detailed timeline tracking milestone dates for raw material lab dips, bulk fabric knitting, printing, assembly, and final inspection.
Inventory Control
Raw fabric lots and trims are barcoded upon arrival, ensuring strict lot traceability, compliance with OEKO-TEX material origin requirements, and preventing shade variations within the same garment batch.
Client Reporting
Weekly status reports containing photographic updates and progress percentages are issued directly to the client's account manager.
In-Process Quality Control
Quality is audited during production, not just at the final packing stage.
Incoming Material Inspection (IQ)
Fabric rolls are tested for weight (GSM), color fastness against washing and perspiration (AATCC standards), bursting strength, and dimensional stability by certified internal laboratory technicians.
Inline Inspection (IPQC)
Quality controllers conduct random spot checks on every sewing line twice per shift, measuring semi-finished panels against critical dimensions on the tech pack.
End-of-Line Audit
100% visual inspection of turned garments for surface blemishes, oil stains, skipped stitches, and asymmetrical panel alignment.
Bulk Production & Order Fulfillment
We manage global logistics coordination from our factory floor to designated port or warehouse destinations.
Packaging Specifications
Garments are packed in individual biodegradable polybags with size stickers, organized into master cartons with shipping marks matching client specifications.
Shipping Terms
We routinely handle FOB, CIF, DDP, and EXW shipments via partnered freight forwarders.
Container Loading
Cartons are floor-loaded or palletized according to client volume requirements, optimizing container space and minimizing transit damage.
OEM & ODM Manufacturing
OEM (Original Equipment Manufacturer)
Production executed strictly according to client-provided tech packs, custom graded patterns, specified trims, and fabric formulas.
ODM (Original Design Manufacturer)
Clients can select from our proprietary catalog of pre-developed activewear designs, functional fabric libraries, and silhouette templates, customized with their brand labels, custom colors, and targeted branding.
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