Orders are received by the office via the telephone, post, fax and email. These orders are then input into the computer and if the garment is a stock garment the order is sent direct to the warehouse to be dispatched. If the garment is a "special", i.e. made for a specific school in as specific style/colour etc. then a production order is created for the factory to produce the garments.
The garment pieces are then overlocked together. First the
sleeves are sewn on to the body and back panels.
Then the back and front panels are sewn together, up the side seam and down the sleeve seam. The garment is inside out at this stage.
The garment is then bartacked i.e. the overlocked ends at the end of each seam are turned back and a half centimetre of stitching is sewn to secure the ends.
The excess thread is snipped off and the garment turned ready for linking. Bartacking ensures that the seams of the garment do not unravel and gives the garment a high quality finish.
The garments are examined to check that the sizing, quality, style and labels are up to the standards set by Charles Kirk. If the garment passes these checks it is folded and bagged, ready for the warehouse.
The completed garments are then packed into boxes in the warehouse ready for dispatch. The garments are checked against the order, to make sure the correct number, colour, size and style of garments are sent.
The garments are then stored ready for dispatch. Most retailers require their garments from May to August as this is the time when the majority of school clothes are sold.
Charles Kirk garments are distributed to independent retailers and school shops all over the United Kingdom.
School children as far away as Canada, Bermuda, Dubai and Kuwait also wear Charles Kirk pullovers.
The yarn used is Courtelle LC which is a speciality acrylic fibre (right)designed to last. Courtelle LC demonstrates superior durability, colour retention and minimal pilling properties making for premium quality school knitwear that is made to endure high demand of wash, wear and tear.
The yarn is knitted into panels on the knitting machines (left). A pullover is made up from a front panel, back panel, two sleeve panels and small panel for the neck. Depending on the school that the pullover is being produced for stripes may be knitted at the neck and/or cuff and/or welt. The panels are checked regularly so that the fabric is knitted evenly for every pullover. The panels are then reviewed as the panel is removed from the machine to check for holes and other faults like striping which can occur if the yarn is failing to meet quality standards.
The panels from the knitting machine are then slit into bodies and sleeves. These parts are then placed in the cutting machine (right)to be cut to size. The cut pieces are then bundled together and placed with the collars in a box. This bundle will then travel around the factory with a ticket identifying the style, size, order number and customer.
This machining takes place on an overlocking machine (left)which cuts off a small amount of excess fabric to give a neat edge.
The collar is then placed on a circular linking machine (right)so that each needle point is placed into a separate rib. The neck of the body is then placed on the needles on top of the collar. The collar is then turned over on the needles and all three pieces are then linked together.
After linking, knitted thread is left on the outside of the garment (left). This unroved i.e. pulled off, so that just the line of the linking thread is left showing.
The ends left on the neck by the overlocking are then sewn together and the edges turned back (right)and secured to give a well formed V at the neck. The label is sewn into the garment at this time.
The pullover is then steamed gently on a wire frame (left)for a short period of time to remove any creases that have appeared during the manufacturing process.
If required the garments are embroidered (right)with the school name and or emblem. This could be a one colour line of lettering or a five colour emblem with lettering.
When the order is due, a delivery note is created and the boxes for that order are collected from the storage area. When the carrier arrives the documentation is checked and then the boxes are loaded. At peak times over 300 boxes leave the factory daily.
