Since the beginning of RezWear, we have been comparing our products to those of our competition. We are constantly trying to see what makes us different by comparing our materials, workmanship and packaging. As an entrepreneur, it is always important to stay up on what's out there. It helps with staying sharp and ahead of the curb.
After several months of logistical issues, things have finally smoothed out and we are on track to exceed all of our initial goals. We are now manufacturing a consistent product that is far above the rest. Through this process though, we have also come to realize that making masks was way more work than we thought it would be.
I thought I would explain the process so that you would get a better understanding of how much hard labor goes into making our masks.
The first step in the process is the design of the mask. Our in house designer creates what the mask will look like and that design is sent to our factory. Once the design has been proofed and approved by us they are then sent to be printed.
Our masks are sublimated. Sublimation is the process of transferring ink (designs) from paper to fabric through heating. All of our fabric starts out white, no matter what color the mask will be. We use a polyester blend for its durability and wash-ability. The ink is printed on a large roll of paper. (Imagine a 7 foot wide roll of paper for your printer.) Then the fabric and the paper are put together and sent through a heated set of rollers which super heats the ink and transfers it to the fabric. The advantage of this is that the color is heated into the fabric and will not wash off, fade or discolor. The color will stay vibrant as compared to screen printing which will eventually wear off. Then the fabric is paired up with another roll of just plain fabric as this becomes the second layer of which our mask is made.
The double layered fabric is now put into a cutting machine, (we have a laser cutter) that will now cut the shapes of the mask to be sewn later. The cut fabric is then stacked up to be sent to the sew shop.
The sew shop is where the masks start to take form. The first person in the line will sew the top and the bottom seams. We use a special loop-type sewing pattern to help keep the edges from fraying. The next sew station is where the pleated sides get sewn. When they are finished, the fabric is sent to the next station where the elastic is sewn on. Finally, the masks are complete and are hand trimmed to remove all of the excess threads.
The masks are then hand counted, bagged and boxed in packages of fifty. This helps us keep count as the packaging department prepares to assemble.
The masks are now placed on a card, slid into the cellophane wrapper, sealed and boxed in carton of 100. The cartons are then brought to the hole punching area where the holes are punched 5 at a time and placed back in the box to be taped and sent to the fulfillment center.
Each day the orders are printed with the packing slips and the masks are packaged and readied for delivery. The post office picks up and off they go to our amazing customers.
So as you can easily see, making our masks is a cumbersome process. But we keep our eye on each step of the process to ensure that we continue keeping the quality standards at the top for our customers.
We hope you enjoy them.
Randy Resnick, Owner