Total Manufacturing Control

Mount Vernon FR fabrics are produced in the company’s vertically integrated manufacturing facility located in Trion, Ga. Vertical manufacturing means that Mount Vernon Mills not just controls, but actually completes the entire manufacturing process – from fiber to finished FR fabrics.

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Mount Vernon FR vs. The Other Guys
Competitors say that they specify the proper base materials, or “greige” fabric for use in producing their FR fabrics, which means they are buying unfinished fabric from a third party. In contrast, Mount Vernon FR manufactures our own greige fabric, resulting in a more consistent fabric weight, width, dye shade and color retention, and overall, a higher level of reliability. When deciding who to buy FR fabric from, consider this: when a company buys rather than manufactures greige fabric, how can the purchaser know for sure where or how well it was woven?

To ensure that every Mount Vernon FR fabric is of the highest level of reliability, quality, durability, color consistency and shrinkage control, the company has total in-house control of more than 25 major processes, including spinning, weaving, dyeing and FR finishing, and uses more than 3,000 computer-monitored control points and extensive quality assurance testing.

Click here to watch a short video of our entire process – from fiber to finished, inspected and tested FR fabric.


The Process

Yarn Production
Denim Warp Dyeing
Weaving
FR Finishing
Testing, Quality Assurance and Inspection
Packing/Distribution


Yarn Production

Opening and Blending

During this process, bales of cotton fiber are separated into smaller tufts, and then blended on each line to produce optimal yarn quality, consistency and strength, which ensures the durability of Mount Vernon FR fabrics.

Opening and blending

Carding and Drawing

In the carding process, foreign matter and short fibers are removed from the cotton. The cotton is then transformed into a sliver, which is a rope-like form. With these slivers, the drawing process creates a single, uniform sliver for spinning.

In the spinning process, slivers are drawn and twisted into yarn and wound into packages.

Drawing process

Watch a video of spinning in action


Denim Warp Dyeing

Yarn passes through a dye range, wash boxes and dye vats, then goes over a skying device in order to allow oxidation to occur. Oxidation allows the color to develop. The yarn is then taken through more wash boxes and a drying device in order to fully saturate and achieve the solid, rich color of our denim fabrics.

Yarn dyeing process.


Weaving

High quality fabric construction is critically important to the comfort and durability of all FR workwear fabrics. Our plant in Trion, Georgia has the capability of running more than 700 looms to produce our Mount Vernon FR fabrics.

Weaving

See a video of weaving


FR Finishing

To guarantee the flame resistant properties of our fabrics for the useful life of the garment, all Mount Vernon FR fabrics are finished in-house in Trion, Georgia.

FR Finishing


Testing, Quality Assurance and Inspection

A vital component of the production process is inspection and testing. Mount Vernon FR fabrics are only sent to customers after being rigorously tested and inspected for quality, durability and flame resistance. A flame is applied to a Mount Vernon FR fabric to ensure it meets or exceeds the standards for flame resistance.

Flame testing the fabric

See the FR testing in action and a side-by-side comparison of Mount Vernon FR fabrics and non-treated fabrics.

Mount Vernon FR treated fabric is able to resist the flame applied to it

Now watch the same test performed on untreated fabric


Packing/Distribution

Mount Vernon FR prides itself on its large, fully automated distribution warehouse, in which it houses up to 15,000,000 yards of fabric, or approximately 55,000 rolls. With this large inventory, you can be sure your orders will be filled and shipped on time or earlier.

MVM Warehouse

Watch our massive warehouse in action