INDUSTRY FRONT
Carolina Leather, based in Pakistan, With over 30 years of expertise, our Ghulam Hussain Tannery produces high-quality leathers like White Crust, OilBlock, ChromeFree, and DrumDie. Our tannery maintains a vast stock of Wetblue Leather and imports premium tanning chemicals to ensure top-notch production.
Carolina Leather values close communication with clients, timely deliveries, and has a strong presence in the USA and European markets, aiming for global business relationships.
CAROLINA LEATHER MANUFACTURING PROCESS
STEP 1: SELECTION AND GRADING
During this step, hides are inspected for defects such as scars, holes, and uneven thickness. They are then sorted into different grades based on quality, with higher-grade leather reserved for premium products. This process ensures only the best materials are used in subsequent stages, maintaining the overall quality of the finished leather goods.
STEP 2: SAMYING
STEP 3: SPLIT
During the splitting process, the leather hides are separated into layers to achieve the desired thickness. This is done using a splitting machine, which divides the hide into a grain layer (top layer) and a flesh layer (bottom layer). The grain layer, being the higher-quality portion, is typically used for the outer surface of leather goods, while the flesh layer may be repurposed for other uses. This step ensures uniform thickness and optimizes material utilization for various applications.
STEP 4: DRUM
In the drum conditioning step, the leather hides are placed in large rotating drums. These drums facilitate the thorough application of various chemicals, such as softeners, dyes, and tanning agents, to the leather. The rotating motion ensures even distribution and penetration of these substances, enhancing the leather’s softness, color, and durability. This step is crucial for achieving the desired properties and finish of the final leather product.
STEP 5: HANGING
In the hanging step, the leather hides are suspended on frames or racks to air dry naturally. This method allows for even drying, which prevents warping and ensures the leather maintains its shape and quality. Hanging also helps in setting the leather’s texture and final appearance. This step is essential for stabilizing the leather before it undergoes further finishing processes.
STEP 6: CHUKRAM
The leather undergoes a buffing or sanding process to smooth its surface and remove any imperfections. This is done using specialized machines equipped with abrasive materials. The goal is to achieve a uniform texture and enhance the leather’s aesthetic appeal. This step also prepares the leather for any subsequent finishing treatments, ensuring a high-quality final product.
STEP 7: DRY SHAVING
The leather hides are precisely thinned to the desired thickness using a shaving machine. This machine carefully removes layers from the flesh side of the leather, ensuring uniform thickness throughout the hide. Shaving enhances the leather’s flexibility and smoothness, making it suitable for various applications. This step is crucial for achieving consistency and quality in the final leather products.
STEP 8 : TAGAL
During the tagal step, the leather is subjected to a detailed inspection to identify and mark any remaining imperfections or areas requiring additional treatment. Workers use specialized tools to mark these spots, ensuring they are addressed in subsequent processes. This meticulous examination ensures that the final leather product meets high-quality standards and is free from defects.
STEP 9: FOOTING/MEASURMENT
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FINAL SELECTION
In the footing or measurement step, each leather hide is measured for its exact dimensions and surface area. This process involves using precise tools to determine the length, width, and overall square footage of the leather. Accurate measurement is essential for quality control and pricing, ensuring that the leather meets the specifications required for various applications and that customers receive the correct amount of material.
In the final selection step, the leather undergoes a last round of quality checks to ensure it meets the highest standards. Each hide is carefully examined for uniformity in color, texture, and thickness, and any remaining defects are identified. The leather is then sorted and graded one last time, with only the best pieces selected for premium products. This step ensures that the finished leather is of exceptional quality, ready for use in manufacturing high-end leather goods.
STEP 10: CUTTING
In the cutting step, the selected leather hides are cut into specific shapes and sizes according to the requirements of the final product. This process uses precision tools and templates to ensure accuracy and consistency. The goal is to maximize the use of each hide, minimizing waste while preparing the leather pieces for assembly in the production of various leather goods, such as bags, shoes, or garments.
STEP 11: SCREEN PRINTING
In the screen printing step, designs or patterns are applied to the leather using a screen and ink. This process involves placing a stencil (the screen) over the leather and using a squeegee to press ink through the screen onto the surface. Screen printing allows for precise and detailed designs, enhancing the aesthetic appeal of the leather products. This step is crucial for adding unique and customized elements to the final leather goods, making them more attractive and marketable.
STEP 12: STITCHING
In the stitching step, the cut and printed leather pieces are sewn together to form the final product. Skilled workers use industrial sewing machines to assemble the pieces with precision and durability. This step involves attaching various components, such as zippers, linings, and handles, depending on the product being made. Proper stitching is essential for the structural integrity and aesthetic quality of the finished leather goods, ensuring they are both functional and visually appealing.
