Current Production Capabilities

Sterlingwear of Boston, Inc. has been producing items for both the United States Armed Forces and commercial interests for over forty years. Throughout this period Sterlingwear has strived to consistently provide a high quality product and on-time delivery to all our customers. In order to achieve this goal, Sterlingwear of Boston, Inc. employs much of the latest technology in the performance of all its contracts, whether they be Government, Commercial or Retail.

Sterlingwear’s contract cut and sew production service is all inclusive from pattern design through packing and shipping. Sterlingwear of Boston, Inc. utilizes numerous automated machines and state-of-the-art technologies including:

• Gerber Accumark Pattern Design System
• Gerber and Lectra automated cutters
• Gerber/Niebuhr automatic fabric spreaders
• GerberMover unit production systems
• automated body pressing machines
• programmable button/button hole machines
• programmable bar-tack machines
• programmable label machines and more.

In addition to advanced production technologies, Sterlingwear of Boston, Inc. has both upgraded and increased its manufacturing space.

In 2005 Sterlingwear moved from its old 60,000 square foot location in East Boston to a new location in East Boston, where it now occupies 150,000 square feet and opened an additional 52,000 square foot location in Fall River in 2007, bringing our total manufacturing space to approximately 200,000 square feet. These attributes allow Sterlingwear to manufacture numerous items at once while still retaining excess capacity to take on additional work.

Sterlingwear of Boston, Inc. currently maintains and employs an experienced and well trained workforce in excess of 350 personnel, with the ability to quickly increase to approximately 450 trained workers if required. This allows Sterlingwear of Boston the flexibility to adjust to fluctuating manufacturing demands and to quickly, efficiently and affordably take your project from design to completion.

Our 30,000 square foot, state- of- the- art Cutting Room features:

• Three automated cutters
• Four, twenty yard long cutting tables with air assist
• One special plaid matching cutting table
• Automatic and manual spreading machines
• Large shade marking area
• Fusing area
• Material storage

Our in-house cutting facility enables us to efficiently cut multiple quantities and types of materials. Our high-ply cutting machines have the capacity to cut up to 3” of compressed goods, which depending on the material cut can be over 100 plies. Our cutting room staff have years of experience cutting and spreading all types of materials and maximizing the utilization of those materials.

By utilizing the Gerber CAD systems we have in place, we are able to input customer supplied patterns directly into our workstations and make any changes if necessary, and create cut markers that make the most efficient use of the material being cut. The markers that are created are then directly inputted into our cutting machines. We have over 40 years of experience in pattern making, grading, and marking, and are able to meet any demands
our customers may have.

With the addition of an in-house designer and our experienced design team, Sterlingwear of Boston has the know-how to take your project from concept to completion. Our design team is constantly creating new products to complement our extensive outerwear line. Our outerwear is sold wholesale to numerous stores, large and small, around the country and around the world, and beginning 3 years ago, in our own retail stores.

Utilizing both progressive bundle and unit production systems, Sterlingwear of Boston is able to produce numerous items at one time with minimal work in process levels and reduced lead times. Sterlingwear has been producing items for the Military and commercial interests for over 40 years. Our team of experienced stitchers and supervisors work together every day to produce a high quality product, in a timely manner. Our goal is 100% customer satisfaction and we work hard each and every day to achieve and maintain that level.

Besides being the sole supplier of the Peacoat to the U.S. Navy, some of our current and past customers include:

• ADS
• U.S. Army
• U.S. Air Force
• U.S. Military Academies
• Military PX’s
• the U.S. Coast Guard
• U.S. Marines

Manufacturing Space

East Boston Facility:
150,000 square feet of total manufacturing space:

• Cutting Room: 30,000 square feet
• First Assembly: 20,000 square feet
• Main Assembly: 70,000 square feet
• Clean and Examine: 15,000 square feet
• Packing and Shipping: 15,000 square feet

Fall River Facility:
52,000 square feet of total manufacturing space:

• First Assembly: 10,000 square feet
• Main Assembly: 30,000 square feet
• Packing and Shipping: 12,000 square feet

Machinery:

• Plain Machines: Singer, Juki, Brother, Mitsubishi: 45-95 machines
• Overlock Machines: Juki, Wilcox and Gibbs: 6-10 machines
• Arm Feed Dbl-Needle Machines: Kansai Special, 10-20 machines
• Bartack Machines: Juki, Singer: 7-15 machines
• Programmable Label/ Velcro Machines: Brother: 6-10 machines
• Programmable Button-hole Machines: Brother, Singer: 5-8 machines
• Programmable Button Machines: Singer, Brother: 3-5 machines
• Eyelet Machines: 1-2 machines
• Snap Machines: 1-2 machines

Estimated Production Capacity:
Sterlingwear of Boston, Inc. is currently producing items for the US Army ( ECWCS GENIII LAYER 7) and for the US Navy (Overcoat, Enlisted), as well as, Berets for the US Army and Air Force. There is also a complete commercial line of outerwear that is sold through e-commerce, retail stores, and wholesale customers. Currently, Sterlingwear is operating at approximately forty (40%) percent capacity with the ability to respond quickly to additional work.

Sterlingwear of Boston, Inc. maintains a workforce of approximately 350 cross-trained, experienced and loyal union employees.