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Carmel Textiles Inc. 

18557 S.W. 104 Avenue  

Miami, Florida 33157

Phone:  786-573-5050

Fax:     786-573-5020

 

MISSION:  To provide our customers an apparel production facility with exceptional quality and service. We are committed to providing the maximum amount of flexibility in sourcing that only a vertical producer can provide. The benefits allow our customers to merchandise products that are profitable and reliable as well as new and fresh in the market at highly competitive prices.                        

 

HISTORY:  Carmel Textiles Inc. was established in 1979 in Miami, Florida. Principals Alan and Steve Stark began their careers as knit machine technicians trained in Stuttgart, West Germany with the Terrot Knitting Machine Company. In 1988 -2000 Carmel expanded it’s capabilities in the US market by providing a vertical knit and dye plant servicing top apparel manufactures. Since 1998 we are active members of the AAPN apparel producer network association. In 2002 Carmel began to operate its facilities in Honduras producing regional knit fabrics and apparel. We operate along with our sister companies Carmel SA Knitting and Creative Apparel in San Pedro Sula, Honduras. In 2004 we expanded our production capabilities to include knitting of body size fabrics.  During this time period we have established strong relationships with local key suppliers. All fabrics are processed and finished in modern, state of the art dye plants.  We have been involved with circular knit production facilities for nearly three decades and have built a sound reputation for integrity and high quality goods. Carmel has been active in developing products in cottons, cotton blends and hi tech synthetic micro-fibers for performance fabrics. We also provide our customer access to GREEN products made from recycled fibers as well as organic and eco friendly natural fibers. The combination of our technical experience and long-term supplier relationships in the industry allow us to deliver a wide range of fabrics, and garments.  We leverage technology, logistics and experience to speed up our product development process and production time to meet current needs of speed to market merchandising. 

 

Product Line:

 

Full Package Garments & Made to Order knits In Circular Knit fabrics

 

Body Styles:   Fashion Tee shirts, sweat shirts and pants, polo shirts, base layer apparel and sportswear. Performance apparel and team athletic styles. Rotary Printed fabrics for lounge wear, sleep wear and active wear.

 

Lead Time: The lead time for orders can vary from as little as 4 weeks to a maximum of 10 weeks for initial orders. The lead time would vary dependent on the type of program that is structured for the individual program. Staging of raw materials can greatly reduce lead time and allow maximum flexibility to manage the supply chain. These programs are structured to facilitate quick response replenishment and maintain a clean, up to date inventory.

 

Re-orders : Customers can work with Carmel to design a quick response program for          re-orders.  We can implement a proactive production plan to manage all levels of raw materials.  This will allow a for a rapid response on quick selling merchandise  as well as a “Change on the Run” adjustments on slow selling products.

 

Minimum Orders Per Style:    Production Orders 850 Dzn of a body  style and minimum fabric dye lots of 1000 lbs per color way. Special test orders for smaller quantities are available and are quoted on an individual basis pending on customer’s needs and raw material requirements.

 

 

Manufacturing Capabilities

 

Sewing

 

Below please find pictures and our factory profile for the sewing facility. Please “Click” on each icon to open presentation

 

Carmel Creative Apparel.pps                 

Carmel Creative Apparel . cutting , sewing , wash.ppt 

 

Embellishment

 

Carmel can provide placement screen-printing with a large assortment of different techniques available. We have capabilities that include up to 12 colors. Techniques include application of glitter, foils, stones as well as discharge printing.  The screen printing facility is located adjacent to a sewing facility which allows us to have a hands-on situation on all print orders. In addition we offer Embroidery as well as appliqués along with print combinations.   

 

Garment Dying and Tie Dying

 

Carmel offers many different types of fabrics specially designed for garment dying. We have specialties that include mechanical blends of different fibers to create fashion forward looks and textures. We can also work with developing new looks specific to each customers merchandising needs. Specialty enzyme washes and pigment and reactive dye techniques are available.  

 

Pre Production Capabilities 

 

Carmel can offer full design services from sketch / concept forward. We keep large assortment of yarns on hand at the mill for new fabric development. We can dye as little as 1 roll of fabric with matching trim at the dye house. We utilize Gerber Technology systems to develop patterns and markers. The factory has in house sample dept with full facilities to screen print and garment wash as needed.

 

Fabrics

 

Carmel manufactures all the knit fabrics used for its garment production. Our mill is in San Pedro Sula, Honduras, which is well located amongst three modern and well-equipped dye houses. Carmel has a total of 44 knitting machines with a weekly capacity of approximately 150,000 pounds.  We have established relationships with key yarn manufacturers both in the Central  American region and the United States. Our relationship with these companies enables us to collaborate on many different levels depending on production needs.

 

Carmel’s Fabric Capabilities in the Region 

 

Fabric Type	Fiber Content	Wt. Range	Yarn Types	Width	Garment  Dye	Rotary Printing
Jersey   18 – 28  gauge	100% cotton     Poly / Cotton   100% Polyester Performance Spandex Blends	115 grm2 –   260 grm2	Open End, Ring Spun, Combed Carded Filament	Body size Wide Tub Flat goods	Yes	Yes , Customer pattern development
Rib  & Thermal	100% cotton    Poly / Cotton  Spandex Blends	185 grm2--    300 grm2	Open End, Ring Spun, Combed Carded	Wide Tub Flat goods	Yes	Yes , Customer pattern development
Fr Terry	100% cotton         Poly / Cotton Spandex Blends	200 grm2--    320 grm2	Open End, Ring Spun, Combed Carded	Wide Tub Flat goods	Yes	Yes , Customer pattern development
Fleece      2 & 3 end	100% cotton    Poly / Cotton	210 grm2 ---  400 grm2	Open End, Ring Spun, Combed Carded	Flat goods	Yes	Yes , Customer pattern development
Pique	100% cotton    Poly / Cotton   100% Polyester Performance Spandex Blends	185 grm2 ---- 300 grm2	Open End, Ring Spun, Combed Carded Filament	Wide Tub Flat goods	Yes	Yes , Customer pattern development
Terry Cloth	Cotton / Poly   100% Polyester	200 grm2 --   320 grm2	Ring Spun, Combed Carded	Flat goods	Yes	Yes , Customer pattern development
Sherpa Fleece	Cotton / Poly   100% Polyester	240 grm2 --   320 grm2	Open End, Ring Spun, Combed	Flat goods		Yes , Customer pattern development
Polar Type Fleece	100% Polyester  Performance Micro Fiber	200 grm2--    320 grm2	Filament	Flat goods		Yes , Customer pattern development

 

 

OTHER FABRIC DETAILS:

 

n      Utilizing USA and regionally manufactured yarns for duty free imports to the US.

 

n       Ring Spinning in combed and carded yarns and Open End carded

 

n      Specializing in “Prepared For Garment Dye”  garments and fabrics

 

n      Mill laundered and distressed fabric finishing available.

 

n      Q/C for fabric shade constancy we utilize Data Color spectrometer to match colors and monitor production lot to lot shade bands of body and trim fabrics.

 

n      Q/C procedure includes all production to be tested for fabric wash stability and shade performance tested in accordance to AATCC standard procedure.

 

n      Providing Soil release and wicking anti- microbial specialty  finishes available

 

n  BRAND NAME PRODUCTS AVAILABLE: DuPont Cool Max performance fabrics; Optmar "Dri-Release" performance fabrics; Wellman  "Comfortrel"; Cotton Incorporated: Endorsed Cotton Knit Fabrics with product hangtag program; Su Pima Yarns:

 

 

 

Other Information

 

     Shipping and Logistics

 

Our main shipping port is the  Port of Cortez on the east cost of Honduras. We can provide LDP merchandise to the port of Miami or any other designated port in the US.

 

We factor our receivables with First Capital Factors and provide open term thru their credit facility.

 

We can provide limited warehousing, pre-packing, hanger and any other packing requirements. Pick and pack program can be structured as well from Honduras and Miami.

 

Carmel is set up with EDI capabilities to facilitate order processing.

 

       Certifications

 

      Our facility is currently certified by:    

       Federated / MMG , Target , Wal-Mart, Levis, Gymboree, Sears

 

      CUSTOMER SERVICE:   Is provided to our customers from our corporate office in Miami. We also deliver weekly W.I.P. reports on production status via email. We are always available to provide technical information to our customers 24/7. All C.S. and technical staff are available on SKYPE internet communications.

 

PRODUCT DEVLOPMENT:    Is coordinated in our Miami office. Development is done in conjunction with our customer service dept and production dept to develop all aspects of the fabric, garment and embellishment.  Factory personnel do in house patterns and utilization makers for added efficiency and control.

 

QUALITY CONTROL: All fabrics are tested at the dye house and in house level prior to processing for: shade match to standard, weight and laundered for wash shrinkage and torque prior to cutting. Shade match is always checked for body and trim match. Garments are checked to garment  measurement specs and also washed in accordance to AATCC 135 test method.

 

 

KEY PERSONNEL:  

 

Alan Stark ...   V.P.  And Principle,  Manages Sales, Merchandising, Product Development alans@carmelknits.com     Cell 305 219 0685       SKYPE:  alanstark29

 

Steve Stark….    President and Principle, Manages Production and Finance      steves@carmelknits.com   Cell 305 219 0684

 

Carmen Rodriguez… Manages Customer Service and Production                 carmenv@carmelknits.com  

 

 

 

 

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