A successful clothing collection starts long before the first stitch is made. The difference between a brand that is growing and one that is stuck due to production problems almost always lies in how the production process is prepared and executed. In this article, we - as a family that has been active in ready-to-wear for more than thirty years - explain how professional textile production works from A to Z.
1. Concept and technical development
Everything starts with an idea, but an idea is not a production file. In this phase, a vague concept is transformed into one tech pack: a technical drawing with dimensions, seam types, material codes, label positions and finishing requirements. A good tech pack will save weeks of corrections and thousands of euros later
What should be included as a minimum:
- Flat drawings front and back, scale 1:1 or 1:5
- Finishing details: stitching lengths, boiler tape, lockstitch versus overlock
- Material specifications: composition, grams per m², shrinkage percentage
- Label position, washing instructions, hang tags
2. Pattern drawing and grading
Based on the tech pack, our pattern department creates the basic pattern — previously on paper, today with CAD software such as Gerber, Lectra or Optitex. The pattern is then graduated to all sizes (XS to XXL). Good grading takes into account shrinkage of the fabric, ergonomics and the target group — we grade a sports shirt differently than a formal shirt.
3. First sample and fit check
Before even one meter of fabric is cut in series, a fit sample made. This first copy is fitted to a mannequin or model. Adjustments to armhole, shoulder seam and waistline are made here. A professional studio expects an average of two to three fitting rounds before the pattern is final.
4. Fabric selection and purchasing
The fabric is selected parallel to the pattern path. Issues such as minimum orders, delivery times and color matching are discussed here. We often work with for small series stock fabrics from our archive; for larger collections we have customer-specific weaving or knitting.
5. Cutting and spreading
When everything is right, the substance becomes spread out in layers of 50 to 200 pieces at a time. An automated cutting machine or an experienced cutter follows the marker layout that utilizes maximum material — with good planning we achieve efficiency percentages of 87% and higher, which is directly reflected in the cost price.
6. Sewing and assembly
The cut parts then go to the sewing line. Depending on the garment, one is used bundle system (one person per operation) or one complete operation (one seamstress makes the entire garment). For premium brands we often choose the second model: shorter lead time, higher finishing quality and better origin traceability.
7. Finishing, pressing and final inspection
The garment is technically finished, but not yet ready for delivery. In the finishing phase, threads are cut, buttons are sewn on, labels and hang tags are attached, and ironing and folding are done. Finally, each piece runs through the QC port: the final inspector checks for functional defects (holes, stains, crooked stitching) and finishing defects based on AQL standards.
8. Packaging, certification and shipping
Finally, packaging is done individually — often in polybags, sometimes in plastic-free alternatives for sustainable brands. When exporting to EU countries, we can supply OEKO-TEX, GOTS or REACH documentation upon request.
What this means for your brand
The steps seem obvious, but the difference is in the discipline with which each phase is carried out. A good manufacturing partner does not come up with shortcuts; on the contrary, he forces you to prepare carefully so that the execution runs smoothly.
Would you like to have your production taken care of by a team with thirty years of experience? Contact us for a no-obligation quote.
