How to avoid the main problem when producing denim products？

Avoid denim production problems

– Bulk color not match the sample

– Bulk shrinkage is unstable, spec is not fit

– Washing takes so long delay the shipment

I believe most of denim buyer or production manager have meet above mentioned production issue, almost every one will see it. How can less the issue?

A piece of jean looks simple, but it is much complex from fabric to a finished products. Many buyer doesn’t know the production process but have to face that why my bulk order feels completely off? Sample looks good, but bulk has various kinds of color shade. And the spec is off and leading customer return, Why? Lets breakdown the above most common issue in denim

1.Color are much different from sample, why?

Normally when making sample, it usually wash separately in small washing machine by a master craftsman while units are less than 10pcs. But in bulk run, it is in a standard machine which usually over 100pcs for one lot. This requires a high level of skill from workers to control the chemical and the use of the pigment, but also the sensitive to the temperature.

In addition, the manual whisker, PP spray, broken holes for bulk are done by ordinary workers, the control of the tools and chemical liquid from each person is different, which results in variations between each piece.

The lack of quantifiable wash standards, poor the washing control experience from workers, and the factory’s overconfidence etc will enlarge the issue.

What need to do?

-One piece bulk sample sign-off to sure the different within the acceptable range

-Checking the first lot color if possible and requiring the shade lot

-Working with washing mill with rich experience and quality control system-

-Selected the right supplier who have standard control of the quality

2.Sample fit is good, but bulk spec is off, why?

The approved sample fit perfectly, but after first washing, it become ripe up or tighten. Even in same pattern but measurement is different. It is most troublesome problem for all denim manufacturers. In fact, sample is sewed in sample room by single person, but in bulk productions, it involves different workers sewing different part, it is one of results inconsistent. In addition, nowadays modern denim fabric contain spandex for comfort wearable feel. However, the spandex will shrink after washing. To know the fabric shrinkage is most important in the denim production. So doing the shrinkage test of bulk fabric is a must in the beginning. Not only one roll of the fabric, need test more to get the average since the cutting pattern is one set.

What need to do?

-Choose the quality fabric not only the color, but also with the stable shrinkage

-Test the average shrinkage of bulk fabric before cutting

-Checking the spec before washing

-One piece bulk sample to do home washing test if have time

3 Why bulk lead time taking so long?

A promised 45days lead time delay to 60days , that miss the sale season. And the rushing production leads to quality issue, like thread ends, smelly or risk of mold. You must understand the denim whole process and sure the approved sample is ready when starting counting the lead time. Most factory lead time 30~45days is base on sample approved and fabric is stock. When approving sample process is delay, that will effected the delivery. Moreover, denim need washing, the hand-sanding, scraping etc need manual. The sales seasons are close, so brands shipping periods will be with a specific time, so that will be a line which need to considering.

What need to do?

-Full timeline planning, make sure to have some more extra buffer time for the washing

-Understanding the the factory’s schedule, make sure sample approved on time

-Sure bulk fabric arrives on time

-Plan the shipment in advance according to the sales season

Denim is not a simple products you need to know it more and understand its characteristic, so that can avoid the problem as much as possible. The problem mentioned above is frequently happen and cause the looses easily. There are many other issue may also arise. What is the biggest denim production issue or mistake you have met? Leave your message,let’s talk about and figure it out.

Preguntas frecuentes

1. ¿Cuánto tiempo se necesita para hacer una muestra?

En Reego, el desarrollo de una muestra no consiste únicamente en coser. Seleccionamos el tejido más adecuado, evaluamos su encogimiento y probamos el color del lavado para asegurarnos de que la muestra cumpla los requisitos. También realizamos una inspección final de todos los detalles antes del envío para que reciba una muestra correctamente terminada.

2. ¿Cuál es la cantidad mínima de pedido (MOQ)?

Además, procuramos reducir los desperdicios a lo largo de todo el proceso como parte de nuestro compromiso con una producción sostenible. Para apoyar a las marcas nuevas, ofrecemos soluciones flexibles de pedidos de prueba que se adaptan a sus necesidades de lotes pequeños.

3. ¿Qué es lo más importante al comenzar una producción de denim?

En Reego, la comunicación es esencial. Antes de comenzar, nuestro equipo de diseño y patronaje revisa todos los detalles técnicos y analiza los puntos difíciles. Esto ayuda a reducir posibles errores y garantiza que el calce, el color y el estilo coincidan con lo solicitado y que el jean pueda fabricarse de manera viable.