Delta Apparel Inc. , Greenville, plans to transfer some of its fabric production for basic T-shirts from its Maiden, N.C., plant to its Ceiba Textiles facility in Honduras, in an effort to lower costs for those products.

The consolidation will reduce fabric production in Maiden by 35 percent and increase it at Ceiba by 8 percent to some 900,000 pounds of fabric weekly. It also is expected to shorten production cycle time and reduce costs by some $1.1 million annually.

The move will result in the loss of 70 jobs at the Maiden plant, which will retain 190 employees to produce fabric for its U.S.-made marketed goods and private-label products along with its Mexico sewing operations.

July/August 2014

PerformanceScrubs.com — a Nashville, Tenn.-based Performance HealthCare Products Inc. company — has invested $4 million to move its Cullman, Ala., manufacturing operations to a 50,000-square-foot, high-tech manufacturing facility in Florence, Ala., approximately one hour from Cullman. The company is offering all of its Cullman employees jobs at the new facility, and hopes to have at least 50 to 60 positions filled by the end of the year, with plans ultimately to employ three shifts comprising 65 workers each.

The new facility features PerformanceScrubs.com’s high-tech, on-demand manufacturing system that automates and integrates almost every component of the manufacturing process and allows for on-demand customization. The company reports its proprietary workflows and complex software will enable it to manufacture millions of garments in any quantity on-demand while reducing inventory costs and streamlining the supply chain. While the facility initially will focus on manufacturing scrubs and sleepwear, PerformanceScrubs.com says the factory model can produce any type of garment.  

“We’ve spent years planning and designing our comprehensive system that has the potential to revolutionize how clothing is made,” said J. Kirby Best, CEO, PerformanceScrubs.com. “The rich history of garment manufacturing in Florence/Muscle Shoals makes this the ideal location to launch a state-of-the-art facility.”

The company’s medical scrubs and sleepwear are made using moisture-wicking; antimicrobial; wrinkle-, stain- and fade-resistant fabrics manufactured by Spartanburg-based Milliken & Company.

All garments, including components, are 100-percent Made in the USA.
 

Conveyor lines at PerformanceScrub.com’s Florence, Ala., manufacturing facility are part of the company’s on-demand manufacturing process and systems.

July/August 2014

Surya Inc., India — a manufacturer of machine- and hand-knotted area rugs and soft goods for the home furnishings market — is investing $30 million to open a U.S. corporate office and distribution facility in Cartersville, Ga., and add 200 employees to its U.S. workforce.  

Surya manufactures its products abroad and ships them to the U.S. for sales and distribution. It has showrooms in major U.S. markets as well as in Toronto and India.

The state-of-the-art, 1,000,000-square-foot facility in Cartersville will handle Surya’s supply chain management, sales, and web creative development services. The company currently has a corporate facility in Calhoun, Ga., and reports that 250 jobs will be retained with the opening of the new facility.

 “Our new facility will enable us to consolidate our product offerings under one roof, providing a highly efficient logistics base and the operational flexibility needed to optimally serve our designer and retailer customers,” said Satya Tiwari, president, Surya, noting that the company has grown significantly over the past several years.” The addition of 53,000 square feet of inviting office space, designed with Surya’s energetic and collaborative culture in mind, will provide a great working environment for both existing employees and new talent as we continue to execute on our strategy to become a $1 billion company.”

July/August 2014