Using the latest technology, its own production facilities, professionalism of the workers, make it possible to produce up to 500 units per shift. We are distinguished by customer-oriented, strict quality control at all stages of the process, automation, transparency and mobility of production (production changeover in less than a day) .
Design of the clothes
Design studio ZIBROO - is a team of creative designers who creates sportswear ZIBROO. At the heart of the creative process - following the latest trends of the world’s sports fashion, making the originality and the desire to bring them a touch of inimitable Kazakh coloring. In addition to developing the collections ZIBROO, Studio performs command and corporate orders, and, if necessary, make designs for new models of working clothes for brand PROFESSIONAL CLOTHES & SHOES.
Following the first, sketch stage, the stage of constructing is going. In the model- design department was successfully implemented computer-aided designing clothes and shoes Grafis (Germany) to 10 jobs. The localized version of Grafis entered the local typology of the figures. You can move away from the GOST, making adjustments to the individual dimensional signs of all sizes, if necessary.
Grafis system automatically reproduce patterns, providing efficiency of their layout and accuracy of increments interdimensional signs . Automatic layout Autonester (Germany) allows you to serve an unlimited number of jobs, making the most efficient layout with the percentage of attacks. Output layout patterns printed on a large-format plotter completely eliminates manual labor and cardboard patterns, which means greatly increase in productivity.
Direct digital printing
Direct digital printing provides the highest quality bitmap images at a low cost. The printed image is deeply eats into the fabric. The finished product can withstand up to 100 wash cycles; and it will not lose its brightness and clarity.
For direct printing on fabric graphic images, we have a specialized printer I-Dot (USA, 2010). The equipment is capable of applying printing on any type of tissue. We use American concern paint DuPont. The work of the whole complex is provided by a single operator.
Thermal printing was designed for all types of fabric. Products with applied thermal printing are used for years. The image does not fade, do not shed and cannot be destroyed for a long time period. The conditions for this are washing in a low temperatures and no-ironing of the products. Thermal printing is performed using a special thermal tape that can be matte or glossy, have a pleasant velvety surface. There are films holographic, iridescent, photoluminescence spectral, reflective, fluorescent, "gold" and "silver", the film Glitter, in the form of leather and skins of wild animals, jeans, and textile.
Thermal Transfer is well suited for application of logos. It is used in a simple processing of cotton, and for synthetic fabrics, as well as on the materials unsuitable for high-quality stencil application. The technology allows you to send clear photo-quality images with accurate reproduction of the color palette. The resulting images are resistant to washing. Prints may include additional elements of decoration or to meet certain application functions. When thermal transfer printing, coloring elements are applied on the paper, then needed area is heated at a temperature of 120 to 190 ° C and finally immediate contact with the surface that needed to be decorated.
Sublimation - one of transfer technologies. For getting a high quality picture, the image is applied to the paper, and then transferred to the fabric using the special heat press at a temperature of 180-230 ° C. Volumetric image is formed. For sublimation printing we use special inks on a natural basis. The paint does not stay on the surface it impregnates it through. The dye penetrates into the fabric fibers; it is fixed there and permanently remains unchanged. Dyed fabric does not lose its elasticity, when stretching or does not break the paint layer. There are no restrictions for the washing.
In the silk-screen printing are used various kinds of colors, the type of which depends on the characteristics of the material that needs to be decorated. Paints can be metal-reflecting or heat-sensitive. Some of these paints, in particular fly ash layer, when hardening forms the surface, similar to the rubber. Used paint is highly plastic, do not crack on knitted fabrics, do not fade with time and are water resistant. Due to the big layer of paint, it turns to very juicy, almost relief image. The product is more than worthy, and will last a long time without losing its characteristics.
Embroidery - the highest quality, stylish and expensive of all methods of drawing. Embroidery is reliable, durable, effective and presentable. Her bright, clear image does not fade or wash off while washing. This is a good solution for the tissue in which it is impossible to apply the image using other methods (as in materials with long pile).
Embroidered graphics on clothing in ZIBROO fully automated: images are transferred to embroidery machines using computer. We have a single head and two eight headed embroidery machines. The high technological level of machines can represent almost any customer needs. For embroidery we use High-quality viscose and polyester threads with many color sets. Stitch can be formed as on the separate piece and on the product during the cut.
The ideal precision cut provides an automated cutting complex Gerber (USA), acquired in 2011. The complex is served by two turns of the table cloth covering. Automation of the cutting process significantly improved the speed of cutting jobs and completely eliminates the human factor error.
Stitches of lining fabrics of outerwear are made with quilting machine, capacity of 25 sq. tissues per hour. Automation of stitch process has reduced involved workers to two persons (machine operators).
Three sewing shops are working on tailoring. One of them- an experimental. Here there is a debugging tailoring of new models and production of test samples, traveling from here to the testing and refinement - until you reach the optimal level of performance of the model. Each shop has 70 jobs, and the total area of our workshops is about 600 sq.
In addition to standard sewing machines, the following applies special industrial equipment manufacturing Zibroo:
Sketches of future Zibroo’s trousers or jackets are created is steps, selected materials and technologies that will be used in its manufacture, designed and thought out all the details and sewed the first sample. It would seem that the new model of sportswear has passed all of the steps from concept to manufacture, and can now go into production. But no: it is time for testing, the results of which will clarify whether the quality requirements fit to the model of Zibroo, or it needs of further refinement.
Model subjected to close examination and assessment by Zibroo’s technologists. If the step is successful, it expects operational check. Products are tested by active sports exercising in natural conditions: in the heat and the cold, the snow, the rain and the scorching sun. Evaluated with wind and water resistance, strength of the product and its insulating qualities, as well as with subjective opinion of people who tested it.
11 steps of quality control:
1. Quality control starts with the managers of the company, taking customer orders and claiming those sketches, model features of the order and timing the delivery of finished products.
2. Supply Division is responsible for the selection of suppliers, purchase of raw materials in line with European standards of quality and fitting and timely supply of raw materials to the factory.
3. Production Manager establishes terms of production and distributes the load.
4. Chief Technologist - careful control and optimization of all processes.
5. The constructors department - quality is determined using the state standards and technical conditions for building construction of the products.
6. Stage layout - control over the directions of drawings and tissue extensibility.
7. Cutting - at this stage there is a culling of textile fabric defects (knots, sprains, scrapes, etc.). Tracking accuracy of the cut specification.
8. Tailoring - Brigadier-technologist monitors compliance with the technical conditions of sewing.
9. Quality Controller monitors the performance of individual operations on each stage.
10. TCI - at this stage the final, the most thorough quality control, checking its compliance with report card measures.
11. Packing plant - the final stage, where we take care of the appearance of each unit of finished product, which will soon go to the consumer.
You can also help us to improve Zibroo clothes. Your suggestions and comments on the quality of the product you have purchased from the brand Zibroo, we are waiting on the feedback line:
tel .: (Almaty ) : +7 ( 727 ) 253 06 33