Where Every
Thread Begins
Two production facilities in Karur and Erode, Tamil Nadu, are home to a complete linen manufacturing pipeline - from raw grey fabric weaving right through to finished, packed hotel and hospital linens.
40+
Imported Sulzer Looms
Weaving unit · Karur
100+
Imported Sewing Machines
Stitching unit · in-house
2
Production Facilities
Karur & Erode
Two Locations. One Complete Pipeline.
Grey yarn arrives at one end - hotel-ready, packed linens leave at the other. Every production step is owned, controlled, and quality-checked in-house.
Main Weaving & Production Hub
The primary facility in Karur, Tamil Nadu is where all grey fabric is woven on 40+ imported Sulzer looms. This unit feeds the stitching and packing operations with consistent raw material.
100+ Machine Stitching Floor
A dedicated stitching floor running with 100+ imported sewing machines ensures high-volume, uniform finishing for hotel bed linen, bath linen, and all soft furnishing categories.
Secondary Finishing & Supply Unit
The Erode production unit completes the pipeline - handling overflow production, finishing, and dispatch for pan-India supply. Together, both facilities form a self-contained manufacturing ecosystem.
End-to-End Manufacturing Flow
Raw Yarn
Grey Weaving
Fabric QC
Stitching
Finishing
Packing
Dispatch
40+ Imported Sulzer
Looms at Work
The weaving unit in Karur is the foundation of all fabric production at Lottus Home Fashions. Imported Sulzer looms are used to produce a wide range of grey fabrics - from basic institutional weaves to premium hotel-grade thread counts - all under controlled production conditions.
Customer specifications for thread count, GSM, and fabric blend are fed directly into the production schedule, so what is woven matches exactly what is ordered.
Imported Sulzer Looms
40+ high-speed imported Sulzer looms are operated to produce consistent grey fabric across thread counts and GSM specifications.
Wide Fabric Range
30×30 / 72×68 construction fabrics to 200TC–450TC fine weaves are produced using 40s, 60s, and 80s count yarn as per customer orders.
Blend Flexibility
100% Cotton, 50/50 PC, 65/35 PC, and 80/20 CP fabric blends are woven to suit hospitality, healthcare, and institutional requirements.
Timely Production Supply
Loom capacity is scheduled to ensure bulk fabric requirements are met on time, supporting stitching unit workflows without bottlenecks.
Thread Count Capabilities
200–260 TC
Budget hotel & hostel
300–350 TC
Mid-range hotels
400–450 TC
Premium / 5-star hotels
100% Cotton
Blend Available
50/50 PC
Blend Available
65/35 PC
Blend Available
80/20 CP
Blend Available
100+ Machines.
Zero Compromise.
The stitching floor at Lottus is where woven fabric becomes a finished hotel bed sheet or a hospital pillow cover - precisely cut, cleanly seamed, and packed to travel anywhere in India.
100+ Sewing Machines
Imported sewing machines are run across the stitching floor to produce uniform, high-speed finishing for all linen categories.
Custom Size Stitching
Bed sheets, pillow covers, duvet covers, and towels are stitched to customer-specified dimensions - no standard-only constraints.
Inline QC at Stitching
Each stitched piece is inspected inline before moving to the finishing and packing stage to catch defects early.
Modern Packing Unit
A dedicated packing area ensures linens are folded, labelled, and dispatched in protective packaging suited for bulk hotel deliveries.
Bulk Order Throughput
Stitching capacity is sized for large institutional orders - 500 to 5000+ pieces per run without compromising on finish quality.
Specialised Machine Heads
Flatlock, overlock, and blind hem machine heads are available for different seam types across product categories.
From Grey Yarn to
Finished Linen
Every step in the production of a Lottus linen is owned in-house. No outsourced stitching, no third-party finishing. The six-step process below is followed for every product, every order.
0
Outsourced Steps
6
QC Checkpoints
14+
Years Refined
Raw Material Sourcing
Premium-grade cotton yarn and fabric inputs are sourced and received at the Karur facility. Every incoming lot is inspected against specification before being accepted into inventory.
Fabric Weaving on Sulzer Looms
Grey fabric is woven on imported Sulzer looms according to the thread count, GSM, and blend specified for each order batch. Consistent tension and weave structure are maintained throughout.
Pre-Stitching Fabric QC
Woven grey fabric rolls are inspected by the quality control department for weave defects, dimensional accuracy, and colour consistency before being released to the stitching floor.
Cutting & Stitching
Fabric is cut to exact dimensions and stitched using 100+ imported sewing machines. Seam type, stitch density, and hem style are applied per product category and customer specification.
Finishing & Inspection
Finished pieces are checked for seam integrity, dimensional accuracy, and appearance. Any piece not meeting the quality standard is flagged and reworked before it proceeds further.
Packing & Dispatch
Approved pieces are folded, labelled, and packed into protective packaging. Orders are consolidated and dispatched from Karur or Erode to hotels, hospitals, and institutions across India.
Checked at Every
Stage of Production
A dedicated quality control department oversees the entire manufacturing process - from raw material arrival to final despatch. Nothing ships without passing through the inspection protocol.
Raw Material Inspection
Yarn and fabric inputs are tested upon receipt for weight, count, and defect rate before being accepted.
Weave Integrity Check
Grey fabric rolls are examined for structural consistency, weave defects, and thread breakage across the roll width.
Dimensional Accuracy
Cut pieces are measured against customer specifications for length, width, and seam allowance before stitching.
Seam & Stitch QC
Seam strength, stitch count, and hem consistency are checked at the inline stitching stage.
Colour Fastness Testing
For hospital and vat-dyed products, colour fastness to wash and light is verified before dispatch approval.
Final Despatch Check
All finished and packed pieces undergo a final count and visual check before the consignment is released.
15+ Product Lines,
One Factory Source
A wide range of hotel, hospital, and hostel linen categories are produced under the Lottus facility - all manufactured in-house to custom specifications and supplied directly from factory to buyer.
Thread count, GSM, size, colour, and fabric blend can all be customised per order. No minimum-run restrictions on repeat orders from established buyers.
Bed Sheets
200TC – 450TC
Pillow Covers
80–150 GSM
Bath Towels
350–675 GSM
Hand Towels
150 GSM
Bath Mats
300–350 GSM
Mattress Protector
80–150 GSM
Duvet / Quilt
200–300 GSM
Bolster
650–900 GSM
Pool Towels
750 GSM
Table Cloth
Custom Spec
Shower Curtain
100% Polyester
Hospital Linen
Vat Dyed
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