K & M International setup a liaison office in India in 1989. A year later, a company under the name and style of BSK Engineers Pvt Ltd was also set up in India by promotors of the US entity to manufacture and export machine parts to USA.
In 1996, this company was renamed BodyGear International Pvt Ltd. In 1999, BodyGear set up a 100% export-oriented toy factory at Edayar Industrial Development Area near the city of Cochin, Kerala, India to manufacture toys and export it to the parent company.
The toy to be manufactured is first developed by BodyGear’s Design Department. This involves creating a toy either from ideas suggested by customers or internally or from sales samples sent by the customer.
The first step of plush toy production is deciding the types of fabric, stuffing and attachments to be used in the toy. These materials will then be bought from reputed vendors after their samples are reviewed and approved.
From sketches of the approved design, cutting patterns are made to obtain maximum number of pieces from a unit area of fabric. These are sent to the fabric cutting section. We have the facility to cut fabric using electrically-heated dies, moving blade cutter and laser cutters and use the appropriate one in each case.
Cut pieces are machine-stitched at the back of fabric. Attachments such as eyes, nose etc are then placed in position and sealed. Stitched toy-skins are then reversed through a small unstitched part on the skin. Compressed fibre from bales is “opened” and the quantity approved by Designers is put into toys using a toy-stuffing machine.
The unstitched part is then closed by hand sewing and the outer surface of the toy is cleaned using wire brushes and compressed air. Each piece is scanned to detect and remove metal particles and toys are packed into polybags and then cartons. Cartons have purchase order data and quantity information printed on them. Packed cartons are loaded into marine freight containers and exported.
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