VIRAKO manufacturing floor
90,000 sq ft · ISO-certified

State-of-the-Art Manufacturing

Our 90,000 sq ft ISO-certified facility in Kalol, Gujarat is vertically integrated from fabric sourcing to finishing — giving us total control over quality, lead times and customization for clients across 32+ countries.

Capabilities

Six core capabilities, one integrated floor

From yarn to your workforce — every step happens under one roof for tighter QC, faster lead times and lower costs.

Precision Cutting

CAD-driven automated cutting machines deliver consistency across runs from 50 to 50,000 units, minimizing fabric waste.

Stitching & Assembly

Industrial Juki machines with triple-stitched seams and bartack reinforcement at every stress point for durability.

Quality Control

In-house NABL-aligned lab tests every batch for fabric strength, FR performance, reflectivity and seam integrity.

Embroidery & Branding

Barudan multi-head embroidery machines for OEM branding, custom logos, names and corporate identity programs.

Packaging & Labeling

Export-grade packaging with compliant documentation, traceability labels and barcode scanning on every carton.

R&D & Innovation

Dedicated R&D cell for new product development, fabric trials, prototype sampling and standard compliance testing.

The Process

Six steps from design to dispatch

A repeatable, audited workflow that scales from sample runs to millions of units without losing precision.

1
STEP 01

Design & Engineering

Safety standards and client briefs become technical specs, patterns and prototypes.

500+
Designs engineered
2
STEP 02

Material Sourcing

Mill-direct FR fabrics, certified reflective tape and medical-grade textiles — traceable and tested.

100%
Raw materials tested
3
STEP 03

Precision Cutting

Automated CAD-driven cutting ensures consistency across production runs of any size.

1M+
Units/month capacity
4
STEP 04

Stitching & Assembly

Skilled operators on Juki machines with bartack reinforcement at all stress points.

1,200+
Skilled operators
5
STEP 05

Quality Testing

In-house lab tests every batch for fabric strength, reflectivity, FR and seam integrity.

14
Test parameters
6
STEP 06

Packaging & Shipping

Export-grade packaging with compliant documentation and on-time global shipping.

32+
Countries served
Equipment Showcase

Industrial-grade machinery, maintained and calibrated.

Our floor is populated with industry-leading equipment from Juki, Barudan and CAD system vendors — backed by preventive maintenance schedules and operator training programs.

VIRAKO manufacturing floor
90,000 sq ft
Integrated manufacturing facility

CAD Cutting System

Automated fabric spreading + precision cutting

Juki Stitching Lines

Industrial lockstitch & overlock machines

Barudan Embroidery

Multi-head 15-needle embroidery machines

Heat Transfer Press

Hi-vis tape bonding & reflective lamination

Ultrasonic Welding

Seam sealing for medical & chemical suits

QC Testing Lab

Tensile, FR, reflectivity & chemical testing

90,000 sq ft
Manufacturing area
500+
Industrial machines
1,200+
Skilled workers
1.5M+
Units per year
Schedule a Visit

Visit our facility in Kalol, Gujarat

See our manufacturing floor, QC lab and embroidery units first-hand. We host buyer visits, third-party audits and partner onboarding tours by appointment.