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Manufacturing Capabilities

Capacity and Equipment

Fleafel operates a 3,600 square metre facility in Tulkarm with 70 people and 50 sewing and quilting machines, plus cutting and finishing equipment. The list below is the equipment on the floor, not a category summary. If a construction is not on it, we will say so.

Capacity: approximately 35,000 pieces per month across a typical mixed order book, equivalent to four forty-foot containers.

Typical month
ProductTypical month, pieces
Pillowcases, pairs10,000
Fitted sheets8,000
Flat sheets7,000
Duvet covers5,000
Table linen2,000
Comforters1,500
Curtain panels1,500
Total35,000
Sewing and quilting
Machine typeStitch, ISO 4915CountTypical operation
Single needle lockstitch30120General assembly, topstitch, label attach
Overlock, three thread5049Edge neatening on cut edges
Twin needle lockstitch3014Flat-felled seams, parallel decorative topstitch
Coverstitch, two needle4064Elastic attaching, channel closing, wide hems
Safety stitch5163Load-bearing seams needing strength and edge finish in one pass
Bartack3043Buttonhole ends, stress points
Chainstitch4012Long seams, fitted sheet hems, high extensibility
Multi-needle quilting3012Comforters, mattress pads, quilted covers
Buttonhole and button attach304 / 1012Duvet cover plackets
Embroidery, six head3011Monogramming, logo application, decorative borders
Total50

Supporting equipment

Cutting and finishing equipment is listed separately and is not counted in the 50.

EquipmentCountFunction
Steam press and folding3Finishing to the fold standard on the tech pack
Straight knife and band cutter2Block cutting
Automatic spreader1Ply spreading to marker length

Stitch and Seam Capability

Thread path diagrams for five sewing stitch types classified to ISO 4915 FLEAFEL CO. FOR TRADING AND TEXTILE IND. STITCH TYPES IN PRODUCTION USE DWG FL-CON-03 REV A / NTS Stitch Types in Production Use Classified to ISO 4915:1991 — thread path shown in cross-section 301 Lockstitch 1 needle thread + 1 bobbin thread General assembly, topstitching, hems, label attachment. needle bobbin Interlacing set mid-ply Balanced, identical both faces. Will unravel if cut. 401 Two-thread chainstitch 1 needle thread + 1 looper thread Long seams, high extensibility, fitted sheet hems. needle looper Looper interlooping, underside Stretches with the fabric. Runs back if the chain is broken. 406 Two-needle bottom coverstitch 2 needle threads + 1 looper thread Elastic attaching, channel closing, wide hems. needles looper Continuous bottom coverage Needle gauge is specified with the stitch, e.g. 1/4 in. 504 Three-thread overlock 1 needle thread + 2 looper threads Edge neatening on cut edges before or during assembly. Loopers wrap the cut edge Trims and encloses in one pass. Seam allowance is set by the knife. 516 Five-thread safety stitch 401 chainstitch + 504 overlock, combined Load-bearing seams where strength and edge finish are both needed. Chainstitch carries the load Overlock finishes the edge One pass, two functions. Reduces handling and operator time. SPECIFYING A SEAM A complete seam specification states, in order: 1. Seam type ISO 4916 designation 2. Stitch type ISO 4915 number 3. Stitch density stitches per cm or per inch 4. Thread fibre, ticket number, colour 5. Needle system and size 6. Seam allowance in mm Fleafel works to the customer's written seam specification. Where none is supplied we issue one for approval before bulk production begins.
FL-CON-03 · Stitch types in production use (classified to ISO 4915:1991) Open full size ↗
Cross-section drawings of six seam types used in bedding manufacture, classified to ISO 4916 FLEAFEL CO. FOR TRADING AND TEXTILE IND. SEAM LIBRARY — CROSS-SECTIONS DWG FL-CON-02 REV A / NTS Seam Library — Cross-Sections Classified to ISO 4916 seam classes; stitch types to ISO 4915 1 Plain superimposed seam ISO 4916 Class 1 — SS Seam stitch 301 Edge neatened, 504 Body seams on duvet covers, pillowcases, comforters. 2 French seam ISO 4916 Class 1 — enclosed 1st pass, faces out 2nd pass encloses raw edge Premium duvet covers. No exposed raw edge, no overlock needed. 3 Flat-felled (lapped) seam ISO 4916 Class 2 — LS Twin needle Both raw edges enclosed High-wear hospitality items. Strongest flat construction. 4 Double-turned hem ISO 4916 Class 6 — EF hem depth 25 mm Raw edge fully enclosed Flat sheet top hem, pillowcase mouth, table linen. 5 Mitred corner hem ISO 4916 Class 6 — EF Excess cut away at 45° Hemstitch or 301 topstitch Table linen, bed skirts, bordered flat sheets. 6 Corded / piped edge ISO 4916 Class 5 — decorative Cord filler Piping foot, stitch 301 Bordered pillowcases, comforters, headboard panels. Cross-sections show material configuration only, per the convention of ISO 4916. Seam allowances and hem depths are set per customer specification.
FL-CON-02 · Seam library, cross-sections (classified to ISO 4916:1991 seam classes) Open full size ↗

A complete seam specification states the seam type to ISO 4916, the stitch type to ISO 4915, the stitch density in stitches per centimetre, the thread fibre and ticket number, the needle system and size, and the seam allowance in millimetres. Fleafel works to the customer written specification. Where none is supplied, we issue one for approval before bulk production begins.

Constructions and Fabrics

ConstructionWeaveYarn countThread count or weightTypical use
PercalePlain40s to 80s combed200 to 400 TCCrisp hand, hospitality and premium retail
SateenSatin60s to 100s combed300 to 600 TCSoft hand and surface lustre
TwillTwill40s to 60s200 to 300 TCDurability, high-wash environments
JacquardJacquard60s to 100s300 to 500 TCWoven pattern, decorative ranges
FlannelBrushed plain or twill20s to 30s160 to 180 g/m²Seasonal ranges
Linen and linen blendPlainn/a150 to 200 g/m²Premium retail

Sizes

Size mismatch is one of the most common reasons a first order fails, and it is entirely avoidable. These are the standard charts for each market.

Fleafel produces to the standard finished sizes of every market it serves, and to house sizes on customer specification. The tables below are the market conventions; the approved tech pack governs.

MarketSizeMattress, cmMattress, inches
United KingdomSingle90 × 19036 × 75
United KingdomDouble135 × 19054 × 75
United KingdomKing150 × 20060 × 78
United KingdomSuper King180 × 20072 × 78
European UnionSingle90 × 20036 × 78
European UnionDouble140 × 20055 × 78
European UnionQueen160 × 20063 × 78
European UnionKing180 × 20072 × 78
US and CanadaTwin99 × 19139 × 75
US and CanadaTwin XL99 × 20339 × 80
US and CanadaFull137 × 19154 × 75
US and CanadaQueen152 × 20360 × 80
US and CanadaKing193 × 20376 × 80
US and CanadaCalifornia King183 × 21372 × 84
Pocket depthDepthFits mattress up to
Standard350 mm300 mm
Deep400 mm350 mm
Extra deep450 mm400 mm

All dimensions are finished, measured flat and relaxed after final press. Hospitality sizes are made to property specification and are not limited to this chart.

Finished product sizes

Fleafel produces to the standard finished sizes of every market it serves, and to house sizes on customer specification. The tables below are the market conventions; the approved tech pack governs.

United Kingdom

All dimensions in centimetres, width × length.

Bed sizeFitted sheetFlat sheetDuvet cover
Single, 90 × 19090 × 190 + pocket180 × 260135 × 200
Double, 135 × 190135 × 190 + pocket230 × 260200 × 200
King, 150 × 200150 × 200 + pocket275 × 275225 × 220
Super King, 180 × 200180 × 200 + pocket305 × 275260 × 220
PillowcaseSize (cm)
Housewife50 × 75
King50 × 90
Square or Continental65 × 65

Where a retailer works to a house size, we cut to the house size.

United States and Canada

All dimensions in inches, width × length. Canada uses the US size set.

Bed sizeFitted sheetFlat sheetDuvet cover
Twin, 39 × 7539 × 75 + pocket66 × 9668 × 88
Twin XL, 39 × 8039 × 80 + pocket66 × 10068 × 90
Full, 54 × 7554 × 75 + pocket81 × 9680 × 86
Queen, 60 × 8060 × 80 + pocket90 × 10288 × 92
King, 76 × 8076 × 80 + pocket108 × 102104 × 90
California King, 72 × 8472 × 84 + pocket108 × 102104 × 96
PillowcaseSize (in)
Standard20 × 30
Queen20 × 30
King20 × 40
Euro sham26 × 26

Duvet covers are cut to customer specification.

European Union

Europe has no single bedding size standard, so this table runs country by country. All dimensions in centimetres.

MarketDuvet cover, singleDuvet cover, doublePillowcase
Germany, Austria135 × 200, 155 × 220200 × 200, 240 × 22080 × 80, 40 × 80
France, Belgium140 × 200200 × 200, 240 × 22065 × 65, 50 × 70
Italy140 × 200, 155 × 220200 × 200, 240 × 22050 × 75, 50 × 90
Netherlands140 × 200240 × 22060 × 70
Denmark140 × 200200 × 200, 240 × 22060 × 63, 65 × 65
Sweden, Finland150 × 210220 × 220, 240 × 22050 × 60, 50 × 70

In Germany the long-standing norm is a 135 × 200 cm duvet cover with an 80 × 80 cm pillowcase. France and Belgium commonly use 140 × 200 with a square 65 × 65 pillowcase that is rarely sold in Germany. Fleafel produces to each national convention.

Measurement point diagrams for flat and fitted sheets with a dimensional tolerance schedule FLEAFEL CO. FOR TRADING AND TEXTILE IND. MEASUREMENT POINTS AND DIMENSIONAL TOLERANCE DWG FL-QUA-01 REV A / NTS Measurement Points and Dimensional Tolerance Where each dimension is taken, and the tolerance applied after finishing 1 FLAT SHEET ① Width ② Length ③ Top hem ④ Bottom hem Measured flat, relaxed, after final press. 2 FITTED SHEET ⑤ Panel width ⑥ Panel length ⑦ Pocket depth measured on the finished corner, seam to hem edge Panel dimensions are taken on the top face, not on the cut blank. 3 TOLERANCE SCHEDULE DIMENSION NOMINAL TOLERANCE METHOD STAGE CHECKED ① / ⑤ Width Per size chart ± 1.5 % Flat, relaxed, steel rule After final press ② / ⑥ Length Per size chart ± 1.5 % Flat, relaxed, steel rule After final press ③ Top hem 100 mm ± 3 mm Steel rule, three points In-line and final ④ Bottom hem 25 mm ± 3 mm Steel rule, three points In-line and final ⑦ Pocket depth 350 mm standard ± 10 mm Corner seam to hem edge Final Dimensional change after wash n/a ≤ 3 % ISO 6330 4N at 60 °C, re-measure Pre-production sample Tolerances are agreed with the customer before bulk and recorded on the approved tech pack. Shrinkage is verified on the pre-production sample, not assumed from the fabric supplier figure.
FL-QUA-01 · Measurement points and dimensional tolerance Open full size ↗

Lead Times

Lead time in bedding is driven by fabric, not by which item is being sewn. The table is structured by fabric route so you can plan against it.

Fabric routeFirst orderRepeat orderNotes
Stock fabric, stock colour45 days30 daysFrom approved pre-production sample
Dyed to your colour60 days45 daysIncludes 25 to 35 days mill lead time
Custom woven or jacquard75 days55 daysIncludes loom setup and first-run approval
Sampling, proto7 working daysn/aFrom receipt of tech pack or reference sample
Sampling, pre-production12 working daysn/aFrom proto approval

All bulk lead times run from approval of the pre-production sample, not from purchase order. Fabric lead time is stated separately so you can see what sits inside the number.

Minimum Order Quantities

Minimums in bedding are set by fabric, not by decoration. Embroidery does not change how much fabric you buy, so it carries a setup charge rather than a raised minimum.

ProductStock fabric, stock colourDyed to your colourCustom woven or jacquard
Fitted sheets2505001,000
Flat sheets2505001,000
Sheet sets150300600
Duvet covers150300600
Pillowcases, pairs5001,0002,000
Comforters150300600
Curtain panels100250500
Table linen3007501,500
Towels5001,0002,000

All minimums are per size and per colourway. A total order minimum of 1,000 pieces applies, so a buyer can spread across three or four sizes and still clear the threshold. Trial orders below minimum are accepted from 50 pieces at a 35 per cent premium on the bulk unit price. Embroidery and custom labelling carry a one-off setup charge, not a higher minimum; digitising is charged once per design and the artwork remains yours.

Fabric Utilisation

Marker layout showing pattern pieces nested across a fabric roll with a utilisation calculation FLEAFEL CO. FOR TRADING AND TEXTILE IND. MARKER LAYOUT AND FABRIC UTILISATION DWG FL-PRC-02 REV A / NTS Marker Layout and Fabric Utilisation How pattern pieces are nested across the roll width to control consumption 1 MARKER ON THE SPREAD SELVEDGE SELVEDGE FLAT SHEET FLAT SHEET FLAT SHEET FLAT SHEET P/CASE P/CASE P/CASE CORNER CORNER CORNER TRIM TRIM TRIM TRIM Usable roll width 275 cm Length Grain direction, all pieces aligned Residual waste 2 UTILISATION Marker efficiency η = Σ (piece area) / (marker length × usable width) utilised waste Target efficiency 90 % Achieved, last audit 88 % WHY THIS MATTERS TO THE BUYER Fabric is the largest single line in the cost of a made-up bedding item. A one-point gain in marker efficiency moves the landed cost further than any labour saving available on the line. Fleafel states consumption per unit in metres on every quotation, so the customer sees the basis of the price rather than a lump sum. Spread height, ply count and marker length are set per order. Shade banding is maintained across the spread.
FL-PRC-02 · Marker layout and fabric utilisation Open full size ↗

Fabric is the largest single line in the cost of a made-up bedding item. A one-point gain in marker efficiency moves the landed cost further than any labour saving available on the line. Fleafel markers to a target efficiency of 90 per cent on 280 cm goods and states consumption per unit in metres on every quotation, so the customer sees the basis of the price rather than a lump sum.

Item, UK King or US QueenConsumption on 280 cm goods
Fitted sheet2.9 m
Flat sheet2.9 m
Duvet cover4.8 m
Pillowcase, pair0.8 m
Comforter shell5.0 m

Sampling

StageWhat it isTimelineCharge
Proto sampleFirst interpretation of the brief or tech pack. Construction and dimensions, not necessarily final fabric or colour.7 working daysUSD 60 per piece plus courier
Pre-production sampleFinal fabric, colour and construction, made on the production line. This is the reference for bulk.12 working days after proto approvalUSD 90 per piece plus courier
Shipment sampleDrawn from finished bulk, sent or retained as the record of what shipped.At packingNo charge

Sampling charges are credited in full against the first bulk order above minimum. Swatch sets are sent free of charge.

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