Thank you for being a customer of Thomaston Mills! The most critical part of our business is you, our distributors. Our job is to quickly provide you with high quality products at the most competitive pricing and make it easy for you to close the sale. While you already know you can sell Thomaston products with confidence, this section will help your sales team close the sale.
This is a resource section for you to better understand our capabilities and sell our products to your customers. We are dedicated to giving you the best tools possible to sell our products and are proud to show the capabilities of our plant and unparalleled team of professionals.
Plant and Customization Capabilities
By Jimmy Bond, Plant Manager
My name is Jimmy Bond. I started working for Thomaston Mills doing yard maintenance in the summer of 1984 while I was in high school. I returned to work later that year in the sewing manufacturing plant as a pillowcase inspector/folder on the afternoon shift. Over the last 34 years, I have had the opportunity to work in many positions. I started as machine operator, and in the Service department, and I worked my way up to Assistant Supervisor in charge of quality, production and safety operations. I then moved up to team leader, instructor, and safety coordinator eventually becoming Shift Manager overseeing the evening shift. Currently, I am Plant Manager overseeing the everyday operations of the facility and its employees.
Like me, over 50% of our employees have over 15 years of experience. Our goal at Thomaston Mills is to provide a better quality product, outstanding lead time and great customer service. No overseas producer of bed sheets can match our team or our ability to save our customers money by delivering high quality linens quickly and customized to their specifications.
Below is a summary of our plant’s production capabilities, machines and customization capabilities:
Pillowcases: 1,300,000 dozen per year
Flat Sheets: 530,000 dozen per year
Fitted Sheets: 380,000 dozen per year
6 Automated L/L Pillowcase Machines
2 Automated W/L Pillowcase Machines
6 Automated L/L Flat Sheet Machines
1 Automated W/L Flat Sheet Machines
4 Automated W/L Fitted Sheet Machines
Sheet Set/Retail Packing Area
Please see our Special Services Price List available for download for more details on our customization capabilities.
Quality Control at Thomaston Mills
By Peggy Coggins, Quality Control Supervisor
I am the Quality Control Supervisor for Thomaston Mills, Sewing Department. I have been in manufacturing since 1972. My first job was sewing flat sheets on a single needle sewing machine. From there, I was an area supervisor and later promoted to Quality Control Supervisor. Over the years, I’ve had the opportunity to work with people from the weaving and finishing plants which helped with my understanding of the defects than can come from those processes.
The products I oversee in our sewing department are pillowcases, flat and fitted sheets sewn on our automated equipment. Specialty items that cannot be sewn on our automated machines are sewn on our separate manual sewing line.
All of our operators are taught how to properly run the equipment and recognize what a “defect” is. Any obvious defect in the finished product is considered a second. These include mill defects, soil, stains, incorrect shade, dye spots, or finished measurements not within tolerance. Seams and rags are removed. Missed defects or unacceptable products found during audits will be removed and corrected before shipping.
Random audits are performed from each machine during the day to ensure our standards are maintained. Quality checks also include monitoring the cut and finished sizes, correct labeling, thread color, hem width, packaging and overall physical appearance.
Excessive defects are reported, so that we can keep records and report problems to the weaving and finishing facilities. Communication is the key to improvement. We also operate a QLL certified lab that enables us to perform more specific testing for superior quality control.
With the help of all of our employees, supervisors, and managers, we are committed to producing products to please our customers.
Manual Sewing Capabilities
By Kawanda Furlow, Supervisor, Manual and Fitted Sheet Sewing
I am just a down to earth southern girl from Thomaston Ga. I am 38 years old, and I have been working for Thomaston Mills for 19 years. I started working on the packing line when I first came to work at Thomaston Mills. I have folded sheets, operated an automated machine, and worked in the supply and ticket rooms before I was promoted to Supply Supervisor. I held the position of fitted sheet Supervisor before my current job, which is Supervisor over the manual and fitted sheet area
In the Manual Sewing Department; we make a variety of products. We make duvet covers, pillow shams, bed skirts, and also manually sewn fitted sheets with drops greater than 15".
When sewing duvet covers, we can either sew them with or without flaps. We usually do a 7" flap on most of our standard duvet covers, although we do have the capability to do any size flap that is requested from the customer. Just send us a sample or design and we should be able to reproduce it!
For pillow shams, we can give you an opening at the top or in the middle of the pillow case. We are capable of giving our customers a 1' flange or a 2' flange. We sew the shams with or without mitred corners. When doing the opening on the pillow sham, we usually sew a 6" or 7" flap. When the opening of the pillow sham is in the middle, it is usually a 20" flap on both sides. However, as with duvet covers, we are able to custom make many sizes with low minimums.
We manually sew travel pillowcases for airplanes. So, when you fly and they give you a pillow, check it out to see if you’re laying your head on a pillowcase that was made by Thomaston Mills.
When we manually sew fitted sheets, it is usually for a pocket that is bigger than a 15" pocket. Our automated equipment can’t go higher than a 15" pocket, so anything bigger than that has to be hand made. Our most frequent request is to sew an 18" pocket. We have also sewn a pocket as small as a 4" on fitted. Even when our machines may not have the capability to get it done, we can always hand sew it on the manual production line. Finally, we also can custom-make flat sheets that do not fit on our automated machines. We have done spa sheets in 45" width and lengths up to 130" on our manual line.
We do not sew anything with a zipper or buttons or a Baratto stitch. We do not have the equipment to finish a product that is calling for one of the three items. But other than that, we can just about manually sew anything that is asked of us to do by our customers.
By Teresa Wyche, Shipping Manager:
I am a native of Thomaston, GA and have been employed with Thomaston Mills for 21 years I have held multiple positions with the company such as a cloth inspector and wash testing cloth samples. I later moved to the shipping department as an order picker, UPS/FedEx clerk and on into a shipping clerk position. After working as a shipping clerk for several years, I became Shipping Supervisor back in 2005 and proceeded to become the 1st female Shipping Manager with the company in 2015.
Shipping and receiving are a vital part of our success. Receiving, inventory control, and filling orders and shipping are the basics of our warehouse operation. As Shipping Manager, I am dedicated to making sure our customers see Thomaston as the fastest and most accurate supplier in our industry.
Once the goods are received and the manufacturing process is complete, our finished products are stored in designated locations in our distribution center. Our system is instantly updated with the finished items. This allows our Sales and Customer Service team to view inventory on hand to fill customer orders and make accurate quotations for our customers.
This task includes printing bills of lading and shipping manifests, picking the correct items and labeling them for shipment. It is very important to pick the right products from inventory and stack them properly on pallets to avoid damage.
We palletize all shipments (except UPS/Fedex and containerized exports) so that cartons arrive in proper condition and to reduce wasted time to our customer in unloading trucks and storing goods in their warehouses. To minimize damage, we recommend that cartons are stacked no more than 60” high and that the total pallet weight is less than 1500 lbs. As our customers generally arrange their own freight details, we can meet their needs but recommend against very highly stacked, heavy pallets to avoid crushed cartons.
Cartons are stacked on a basic 40 X 48” pallet with less than 1” overhang and secured by wrapping to ensure that all cartons stay together and thereby minimizing damage and the risk of lost cartons. We also offer non-palletized shipments by customer request and shipments via UPS and Fedex.