Manufacturing process

From thread to fabric roll

At Porcher Sport, the manufacturing processes are totally integrated within our factories, filled with modern and productive machinery: at least 6 manufacturing steps are needed to convert a thread into a high performance fabric. A particular attention is given to controlling our processes in order to guarantee perfect consistency in the quality of our products. 

Furthermore, at every manufacturing step, the products are checked according to the most rigorous quality standards.

Our R&D engineers are also within close proximity to our industrial equipment. This way, by taking advantage of all the synergy between the various competences, from conception to manufacturing, we have a unique ability to innovate rapidly and efficiently within the relevant sporting activities.

 

For the SKYTEXTM fabric, it is a high tenacity polyamide 6.6 thread. The first step, the warping, consists of unwinding the thread from the bobbins through a resin bath, the function of which is to protect the thread during weaving.

 

Preparation for weaving

To manufacture a very light fabric such as SKYTEXTM, around 10,000 threads are wound in parallel around a large bobbin - this is the warp of the fabric-to-be. One by one, theses threads are knotted to the previous warp, on the loom. It is done manually as no machine can replace the dexterity of our machinists.

 

 

 

 

The weaving principle has remained the same over the millenniums: the crisscrossing of the warp threads (lengthwise) and the weft threads (crosswise). Notable difference to manufacturing by craftsmen: on our latest generation looms, the weft thread is propelled at around 100kph between the warp thread, thanks to a fine and powerful air jet.

 

Wound around an enormous bobbin, the textile is transferred into an autoclave. Inside this gigantic « pressure cooker », the fabric is washed free off its protective layer, ready to be dyed.

 

During the next stage, the thermofixation, the fabric shrinks in a controlled manner under heat to become dimensionally stable. Then comes one of the most important steps: coating. It is the secret formula of this resin, when applied uniformly with a precision down to a gram per square meter that more or less determines the product's performance.

 

Before being delivered, the fabric goes systematically through several steps of quality control. An initial visual control allows to detect the tiniest defect and to isolate if needed a batch that does not match our quality standard. Furthermore, samples are taken regularly for a thorough property analysis in our lab.