Behind the Scenes at GG Zippers: A Factory Tour of Our Polyester Zipper Roll Production
Welcome to GG Zippers – where precision meets performance, and quality begins at the core. As one of India's trusted CFC zipper manufacturers, we’re proud to take you on a step-by-step behind-the-scenes tour of how our polyester zipper rolls are made. From the very first strand of yarn to the final packed roll ready for shipment, each stage is handled with care, expertise, and a commitment to excellence. Let’s dive into the world of zippers and explore the complete journey of a GG Zipper.
Step 1: Loom Section – Where It All Begins
The journey of a zipper starts with the loom. In this section, high-strength polyester yarns are transformed into narrow fabric tapes using our advanced narrow fabric loom machines. These tapes are the foundational material for every zipper. Our looms operate with speed and precision to ensure consistency in width, density, and strength. Each roll of tape undergoes a quality check to ensure there are no flaws in the weave, as even the slightest imperfection can impact the final product. This is where durability begins.
Step 2: Chord Section – Twisting Strength Into Shape
Next, we move to the Chord Section, where multiple polyester yarns are twisted together using specialized twisting and winding machines. This creates a single, strong chord that will soon become the inner structure of the zipper coil. The chord must be consistent in twist tension to ensure strength and flexibility. It’s a critical hidden component that provides the zipper with its lasting strength. Without a well-made chord, the coil wouldn’t hold its shape or endure heavy usage.
Step 3: Coiling Section – Forming the Coil
This is one of the most fascinating parts of the process. The coiling section is where polyester monofilament yarn is formed into a continuous filament coil (CFC). At the coil forming machines, the monofilament yarn is wrapped around the chord and shaped into a spiral coil. This coiled structure is what gives the zipper its interlocking mechanism. It’s a delicate process where uniformity and alignment are key. Every loop must be identical, every twist must be perfect. This is the beating heart of the zipper.
Step 4: Twisting Section – Preparing the Stitching Yarn
While the coil is being formed, we simultaneously prepare the stitching yarn – the thread that binds the coil to the tape. In the Twisting Section, fine polyester filaments are twisted into a strong and smooth sewing yarn. This yarn needs to be resilient yet soft enough to pass through the coil and tape without damaging them. Precision machines ensure the right number of twists per inch to give it maximum strength.
Step 5: Stitching Section – Bringing It Together
Now comes the moment of assembly. In the Stitching Section, the coil is stitched onto the woven tape using the specially prepared sewing yarn. High-speed, computerized stitching machines ensure that the stitching is tight, secure, and evenly spaced. The result is a raw zipper – not yet dyed or finished – but fully functional. At this point, the zippers are ready to take shape and color. Quality inspectors closely examine each batch to check for missed stitches, misalignment, or gaps in the coil.
Dye Matching Lab – Where Colors Come to Life
Before the zippers can be dyed, we need to ensure the colors are just right. At our in-house Dye Matching Lab, we receive fabric swatches or Pantone codes from customers and develop exact color recipes. This lab is equipped with modern tools and experienced technicians who ensure perfect color matching. This stage is critical for our fashion, bag, and garment clients who rely on us to match their brand colors exactly.
Step 6: Bobbin Winding Section – Getting Ready for Dyeing
Once the zippers are stitched and the color recipe is prepared, the raw zippers are wound onto 32-inch bobbins. The winding must be done evenly to ensure uniform dye penetration. We take great care to wind the zippers with consistent tension, avoiding overlapping or loose ends. Each bobbin is marked with a color code and batch number to maintain full traceability.
Step 7: Dyeing Section – Transforming With Color
With the bobbins prepared, we move to the Dyeing Section. Here, the bobbins are loaded into high-capacity dyeing machines that use steam and pressure to dye the polyester zippers. Our dyeing process is eco-friendly and efficient, using minimal water and chemicals. The steam dyeing process ensures vibrant, long-lasting color that doesn’t fade or bleed. Multiple quality checks are conducted at this stage to ensure color consistency across batches.
Step 8: Hydro Extraction Section – Spinning Out Excess Water
Post dyeing, the zipper tapes are still soaked. They are transferred to our Hydro Extraction Section where they are spun at high speeds to remove excess water. This step is crucial to ensure that the zippers dry faster and evenly in the next stage. The high-speed centrifugal force extracts moisture without damaging the delicate tape or coil. This stage also helps in preserving the dye's integrity and preventing blotches.
Step 9: Heat Setting Section – Drying and Locking the Shape
Once excess moisture is removed, the bobbins are moved into large heat-setting or pressing machines. These machines use precise temperatures to dry and press the zippers into their final structure. Heat setting not only dries the tape but also locks the coil and tape into their final shape, improving the zipper’s appearance and functionality. The tapes are stored in clean containers after this process to cool down before rolling.
Step 10: Rolling & Packing Section – Final Touches
At this point, the finished zippers are rolled into spools of 100 yards, 200 yards, or custom lengths as per customer requirements. Our packing staff then seals each roll into LDPE polybags bearing the GG Zippers branding. This packaging protects the zippers from moisture, dust, and handling damage during transportation and storage. Every roll is labeled with size, type, color, and order details to ensure smooth dispatch and tracking.
Step 11: Bagging Section – Packing for the Journey
Now the packed rolls are grouped and bagged according to the customer’s shipping preferences. For domestic orders, we use strong PP woven sacks. For international shipments, we use heavy-duty corrugated boxes for better protection during long transit. Our packing team ensures that each bag or box is sealed, labeled, and stacked carefully to avoid any movement or damage.
Step 12: Dispatch & Loading Section – Ready to Ship
Finally, the packed zipper rolls move to our Dispatch Section. Here, all final documentation is prepared, including invoices, packing lists, and shipping labels. Once everything is cleared and approved, the orders are loaded onto trailers, containers, or trucks depending on the destination. Our dispatch team ensures timely handover to logistics partners and keeps our clients informed at every stage.
Why This Process Matters
Each step in this journey reflects our dedication to quality, efficiency, and customer satisfaction. By investing in modern machinery, skilled workers, and rigorous quality checks, we make sure every roll of GG Zippers meets international standards. Whether you're a bag manufacturer, garment maker, or industrial supplier, you can rely on us to deliver zippers that are strong, consistent, and perfectly matched to your needs.
Visit Us – Experience the GG Zippers Difference
We invite you to visit our factory in Meerut to see this process live. For clients who can’t make it in person, we also offer virtual tours. Get in touch with our team to book a slot and see how we turn simple polyester yarn into world-class zippers.
For any inquiries or custom requirements, call/WhatsApp us at +91-8791010316.
Thank you for joining us on this factory tour. We look forward to partnering with you in your zipper journey!
Get in Touch
📍 Manufacturing Unit: PREM POLYTEX, S-8, Delhi Road, Industrial Area, Partapur, Meerut - 250103, U.P., India
📍 Corporate Office: A-7, The Meerut Mall, Delhi Road, Meerut - 250002, U.P., India
📧 Sales Enquiry: sales@ggzippers.com
📧 Support Enquiry: support@ggzippers.com
📞 Phone: +91-8791010316
Explore our polyester zipper rolls collection and experience the GG Zippers difference in quality, flexibility, and performance! Contact us today for bulk orders or custom inquiries.
