Machine Calibration
Devices are verified weekly to ensure accurate weight output.
Chemical Inventory & Planning
Efficient inventory planning is essential to avoid production delays. We maintain real-time stock updates using ERP systems and forecast requirements in advance to ensure smooth operations.
Chemical Weighing & Issuance
Before releasing chemicals to the dyeing floor, each one is weighed precisely according to the job card. This ensures batch accuracy, maintains fabric quality, and aligns with safety and compliance standards. The entire issuance process is monitored, documented, and approved by authorized personnel.
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Issuance Protocol
Each release requires proper sign-off and tracking documentation.
Quality & Safety Protocols
We follow strict safety and quality checks for chemical storage, usage, and return, complying with industrial and environmental norms.
- MSDS
- Approval
- Labeling
- Housekeeping
Testing & Approval System
New chemicals are first tested in the lab for shade and performance. Upon approval, they are recorded and integrated into bulk usage protocols with verified documentation.
Embroidery Pre-Dyeing Process Overview
At Rudra Sustainable Solutions, we provide expert consulting for embroidery units with a focus on structured design development and efficient sampling execution. Our pre-dyeing process framework ensures each design passes through technical, creative, and market validation to reduce errors and increase production success.
✅ What’s Included in Our Pre-Dyeing Consulting:
Design & Sampling Development
We help you structure your design creation process—from outline to sampling—with proper approvals and error checks.Digital Punching & Transfer
Every embroidery design is digitally processed using punching software and transferred accurately to machines with documented approvals.Concept to Prototype Execution
We guide your team through idea generation, market research, feasibility checks, and sample development for client validation.Risk & Quality Analysis
Detailed analysis for design feasibility, cost impact, stitching accuracy, market viability, and compliance with legal requirements.
🧵 Fabric Process Flow Overview
Our Fabric Process Flow SOP ensures every batch meets the highest standards—from initial inspection to final issuance. With strict quality audits, real-time tracking, and lab testing protocols, we guarantee consistent performance, efficiency, and transparency across the supply chain.
Key Highlights:
✅ FOB Package Approval
Fabric packages are received and verified within 2 days of FOB approval to avoid delays.
✅ 10% Fabric Audit
Every fabric batch undergoes a 10% quality check using a 4-point inspection method.
✅ Lab Testing & Reports
50 CM fabric samples are lab-tested within 48 hours to ensure GSM, shrinkage, and dye consistency.
✅ Lot Card & Color Check
Color continuity, GSM, and internal shrinkage are reviewed and documented for every lot.
✅ Rejection & Escalation Process
Rejected lots are sent back to HO/Mill with proper documentation and audit trail.
✅ Cutting Plan Coordination
Cutting and trimming are issued as per ERP challans—no manual slips allowed.
✅ Final Fabric Closure
All data is logged and summarized in the final closure report within 7 days of supply.
🧾 Polyester Fabric Audit SOP Overview
At Rudra Sustainable Solutions, we follow a meticulous fabric auditing process that ensures every meter of polyester fabric meets client expectations and compliance standards. From initial 4-point inspections to final dispatch, each step is verified, reported, and quality-assured through defined protocols.
🔍 Key Quality Audit Steps
✅ Initial Fabric Inspection
Each fabric roll is checked immediately upon receipt using a 4-point system and defect cards.
✅ Supplier & Customer Communication
If defects are found, audit reports are shared via email, and reinspection meetings are conducted.
✅ Internal Audit & Lot Checks
Post-finishing, the internal team audits lot files to recheck color, GSM, width, fill, and shrinkage.
✅ Defect Review Meetings
Critical defects are discussed with production and quality teams for correction and escalation.
✅ Short Interval Control (SIC)
SIC is applied at every machine stage to monitor real-time process consistency and quality.
✅ Pass/Reject Decision Flow
Based on SIC reports, fabric either moves to the next process or returns for correction.
✅ Final Decision & Closure
Audit issues are resolved within 24 hours, corrective action is taken, and decisions are finalized.
🎨 Color & Chemical Department SOP Overview
This SOP outlines the end-to-end process followed by the color and chemical department at SJDMPL, ensuring proper documentation, inventory tracking, and process flow through ERP systems. Every activity from procurement to usage is monitored and recorded by responsible heads to maintain consistency, accuracy, and traceability.
🔹 Key Operational Highlights
✅ ERP-Based Record Maintenance
All monthly and process records are maintained digitally in the ERP for traceability.
✅ Department-Wise Responsibility
Tasks are distributed among Purchase Managers, Lab Managers, Production Heads, and Chemical Heads.
✅ Material Receiving Logs
Each time chemicals or colors are received, entries are updated in ERP immediately.
✅ Job Card Integration
Post-process usage data is linked to job cards for accountability.
✅ Annual Maintenance Records
Heads maintain yearly chemical and material usage logs.
✅ New Chemical Approvals
Every new chemical purchase requires detailed recording in ERP.
🧪 Laboratory SOP – Color & Fabric Testing
Our Lab SOP ensures that every dyeing and finishing process at SJDMPL adheres to ISO standards with systematic recipe preparation, rigorous testing, and accurate reporting. The lab plays a crucial role in ensuring quality consistency through physical and chemical analysis before fabric reaches production.
🔬 Key Lab SOP Highlights
✅ Daily Shade Recipe Preparation
Lab managers prepare recipes using spectrophotometers for both cotton and polyester fabrics.
✅ Sample Analysis & Final Approval
Lab dips are analyzed and finalized before submission to clients, with proper records maintained.
✅ Post-Finishing ISO Testing
After finishing, every lot undergoes ISO-standard tests for physical and chemical properties.
✅ Test Report Generation
Lab heads generate and verify test reports for each lot and maintain all analysis logs.
✅ Trial Reporting
In case of any requirement deviation or issue, special trial reports are created and analyzed.
✅ Machine Calibration & Maintenance
All lab equipment must be calibrated regularly and certified by QTEX.
✅ Documentation & Archiving
Monthly records and test results are systematically stored and reviewed.
🌾 Cotton Department SOP Overview
Our Cotton Department SOP defines a clear workflow from order confirmation to production execution. With a focus on ERP integration, internal job cards, and Short Interval Control (SIC), every activity is tracked and documented to ensure smooth, efficient cotton processing aligned with industry standards.
📌 Key Highlights from the Cotton SOP
✅ Order & PO Management
Orders are updated in ERP immediately after buyer confirmation and internal POs are generated for tracking.
✅ Watch Cards & Job Cards
Warehouse managers create watch cards after PO reception and maintain job card logs post-loading.
✅ Weekly Reporting
Marketing teams and cotton heads share weekly status via email to maintain process transparency.
✅ Pre-Production Planning
Supervisors generate reports before any production begins to prevent delays and errors.
✅ SIC + Linewalk Monitoring
Operators perform Short Interval Control and linewalks at each machine to ensure workflow consistency and issue detection.
✅ Multi-Stage SOP Compliance
Every operational step—from loading to execution—is covered under SOP with mandatory SIC reporting.
🧵 Polyester Department SOP Overview
This SOP ensures a structured and accountable flow of operations in the polyester fabric processing unit—from internal PO generation to drumming, temperature control, and quality checks. Each role is clearly defined, monitored through SIC and line walks, and integrated with ERP documentation for complete transparency.
📌 Key Highlights
✅ Weekly Planning & PO Generation
Marketing and PPC teams plan every Saturday and update PO details in ERP.
✅ Fabric Receiving & Documentation
Fabric is received post-lab dip approval and all records are maintained digitally.
✅ Pre-Production Meetings (PPM)
Discussions on GSM, width, and color accuracy take place before bulk production begins.
✅ Drumming Process with Quality Supervision
Operators fold and treat fabric based on customer requirements under supervisor guidance.
✅ Temperature & Machine Monitoring
Temperature, chemicals, and water levels are checked every hour to avoid deviation.
✅ SIC & Line Walk Enforcement
All departments conduct Short Interval Control and machine line walks at every process stage.
✅ RFD & Dyeing Protocols
Fabrics are scoured at 130°C to remove impurities before proceeding with dyeing.
✅ Recipe Matching & Final Inspection
Aero dyeing ensures color consistency and quality, matching approved lab dips.
🧾 Polyester Audit SOP & Quality Flow Overview
Our Polyester Audit SOP outlines the complete quality verification and audit process from fabric arrival to final decision. Every stage is backed by reports, defect tracking, client-supplier feedback, and Short Interval Control (SIC) to ensure compliance and zero defect dispatches.
✅ Key Operational Highlights
4-Point Fabric Check
Every fabric roll is audited immediately upon arrival using 4-point defect cards and system reports.Defect Identification & Communication
Defects are reported to both production and quality teams, followed by internal review and customer-supplier communication.Internal Audit & Lot Review
Once fabric is finished, internal audits verify GSM, color, shrinkage, width, and lot parameters before final approval.Internal PPM (Pre-Production Meeting)
Issues identified during audits are discussed and resolved internally across departments.Lot Testing & Decision
Each lot is sent to the lab and reviewed before acceptance. Rejected lots undergo defect re-meeting.Short Interval Control (SIC)
SIC is implemented at each machine stage to monitor real-time process quality and avoid defects.Approval & Dispatch Decision
Final decisions must be made within 24 hours. Approved lots are dispatched; unapproved ones are reprocessed or rejected.
🧾 Polyester Audit SOP & Quality Flow Overview
Our Polyester Audit SOP outlines the complete quality verification and audit process from fabric arrival to final decision. Every stage is backed by reports, defect tracking, client-supplier feedback, and Short Interval Control (SIC) to ensure compliance and zero defect dispatches.
✅ Key Operational Highlights
4-Point Fabric Check
Every fabric roll is audited immediately upon arrival using 4-point defect cards and system reports.Defect Identification & Communication
Defects are reported to both production and quality teams, followed by internal review and customer-supplier communication.Internal Audit & Lot Review
Once fabric is finished, internal audits verify GSM, color, shrinkage, width, and lot parameters before final approval.Internal PPM (Pre-Production Meeting)
Issues identified during audits are discussed and resolved internally across departments.Lot Testing & Decision
Each lot is sent to the lab and reviewed before acceptance. Rejected lots undergo defect re-meeting.Short Interval Control (SIC)
SIC is implemented at each machine stage to monitor real-time process quality and avoid defects.Approval & Dispatch Decision
Final decisions must be made within 24 hours. Approved lots are dispatched; unapproved ones are reprocessed or rejected.
📦 Incoming Material SOP – Fabric & Chemical Handling
Our SOP for incoming materials ensures that every consignment—be it fabric, chemicals, or accessories—is properly received, verified, documented, and stored with full traceability. From unloading to inspection, and documentation to storage, all steps follow compliance-driven protocols for consistent quality and inventory control.
🔍 Key Process Points
✅ Unloading & Physical Verification
Materials are unloaded using proper tools and inspected for quantity and packaging accuracy.
✅ Quality Inspection Team
All materials undergo verification against predefined quality standards before approval.
✅ Procurement Coordination
Purchase team ensures supplier details, batch numbers, and delivery records are properly documented.
✅ ERP-Based Documentation
Every batch is logged with GRN entries, batch tracking numbers, and supplier information.
✅ Warehouse Storage Protocols
Materials are stored as per type, size, and condition, ensuring FIFO (First-In-First-Out) usage.
✅ Handling & Compliance
Instructions are followed to prevent contamination, damage, or non-compliance with safety norms.
🔧 Singing Machine SOP – Fabric Finishing Guidelines
Our SOP for Singing Machine operations outlines the exact speed and burner settings required for different fabric types to ensure optimal finishing quality. At Rudra Sustainable Solutions, we help textile mills achieve consistent results, minimize fabric damage, and maintain high production efficiency with machine-specific process parameters.
⚙️ Key Parameters by Fabric Type
✅ Rayon 30′ – Speed: 55 m/min, Burner: 6mm Up
✅ Cambric 60′ – Speed: 70–75 m/min, Burner: 4.5mm
✅ Cotton Wale – Speed: 80 m/min, Burner: 3mm
✅ Cotton Twill – Speed: 55–60 m/min, Burner: 4.5mm
✅ Rayon Twill – Speed: 50 m/min, Burner: 6mm
✅ Cotton Flex – Speed: 55 m/min, Burner: 4.5mm
✅ Cotton Poplin – Speed: 45 m/min, Burner: 6mm
