State of the Art Production Facilities

100% Vertical Fabric mill

The efficient utilisation of resources is the guiding principle of Neela. Our goal is to become the most efficient organisation in every aspect whether it is Water, Human Resource, Electricity or Raw Materials, by focusing on the input-output ratios of all our resource inputs.
Yarn Manufacturing

From Cotton to Spun Yarn

We get all of our cotton directly from the source from cotton growers and ginners in a sustainable and responsible way.

Opening and cleaning is the first step in preparing the cotton to be made into yarn. Highly compressed bales come with some leaf particles from the cotton plant. The Top feeder then picks off a layer of fibre and feeds it to the cleaning machine, which opens, blends and fluffs the fibre.

During the carding process, the cotton is further cleaned and aligned, the weight kept as a constant. A mat of fibre is fed into the card. The metallic wire covered cylinders parallel the fibres. A very thin layer of fibre called a web is carefully removed from the cylinder and condensed into a fragile rope called a sliver.

Slivers continue onto the drawing process which blends slivers together for better weight uniformity. Six strands of card sliver are combined to produce one strand of drawing sliver. The process further straightens the fibres ready for the roving process.

The roving process drafts the drawn sliver into a smaller and finer form that will fit on a spinning frame. For every inch of drawing sliver fed, four inches of roving are produced.

Ring Spinning uses a robotic conveyor that moves the finished bobbins to the next process untouched by human hands. The roving is further drafted and twisted, taking the shape of thread, which is referred to as yarn. Special computerised attachments on the spinning frame allow us to add thick places or slubs to the yarn to create a vintage denim appearance.
Fabric Manufacturing


The warp yarns are dyed before the fabric is woven. Rope dyeing, or long chain dyeing is a process unique to the application of indigo. The ball warps are loaded at the entry end of the range and are processed through a series of boxes, which contain indigo dye. After each box or dip, the ropes are exposed to the air, where oxidation of the dye takes place.

The purpose of beaming is to separate and parallel the dyed yarns from the original rope form and wind them onto a section beam. The rope is pulled and combed, the warp ends are separated and paralleled and wound onto the section beam for the slashing.

In preparation for weaving, a protective coating of starch called warp size is applied to the warp yarns. This coating is applied to give the warp yarns the strength and flexibility to withstand the stress and abrasion of weaving.
Fabric Manufacturing

Weaving & Finishing

Weft yarns are interlocked with warp yarns during the weaving process. High-speed looms propel the weft yarns through the shed in different ways depending upon the machine type. A warp of more than 2000 yards is woven into one continuous roll of fabric ready for finishing.

Finishing involves processing the fabric through a continuous range where desired shrinkage and stiffness levels are achieved. Finishing also gives the fabric a desired surface effect and sets the desired width. It is during the finishing process where skew is added to the fabric to prevent leg twisting in garments. The warp shrinkage of the fabric is established at the sanforizer.
Yarn Manufacturing


In addition to quality testing and inspections conducted throughout the entire manufacturing process. Operators inspect each yard of denim.

Controls are in place for each process from dying to finishing to ensure we meet the correct standards. We use sophisticated equipment in our labs to monitor shrinkage, weight, strength and shade.

Once everything has been tested and checked for quality our fabric is ready to be shipped directly to you.

Always up to The Mark

Delivering at the highest standard is at the core of Neela. To make sure we deliver the best products to our clients, we are always make sure to catch up with new standards in the industry.
BCI Cotton Logo
GOTS - Global Organic Textile Standard Logo
Global Recycling Standard (GRS) Logo
Gold LEED Logo
OCS 100 - Organic Standard Content Logo
RCS 100 - Recycled Claim Standard Logo
REACH Compliance Logo
SA 8000 Certificate
Standard 100 by OEKO-TEX Logo

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