Manufacturing Process
From tech pack to finished product: Our complete cut and sew manufacturing process.
Production Quick Reference
20-30 Day Timeline
From approved tech pack to finished goods ready to ship
6-Stage Process
Tech pack review, cutting, sewing, printing, QC, export
Full Customization
Printing, embroidery, washing, labeling, packaging
Complete Production Workflow
Every order follows a structured production process with quality checkpoints at each stage. We maintain transparency throughout, keeping you informed of progress.
Tech Pack Review & Sampling
We begin by thoroughly reviewing your tech pack, including design specifications, measurements, fabrics, and any special requirements. We then produce samples for your approval before proceeding to bulk production. This ensures we understand your exact requirements.
- Tech pack analysis and clarifications
- Fabric sourcing and GSM verification
- Sample production and fit adjustments
- Final sample approval before bulk order
Pattern Making & Cutting
Our experienced pattern makers create accurate patterns based on your approved specifications. Fabric is then spread and cut with precision using industrial cutting equipment. We maintain strict quality control on fabric quality and cutting accuracy.
- Professional pattern making and grading
- Fabric inspection and preparation
- Industrial spreading and cutting
- Cut piece inspection and bundling
Sewing & Assembly
Skilled operators assemble garments using industrial sewing machines. Each workstation focuses on specific operations for efficiency and consistency. We follow your construction specifications precisely, from seam types to stitch counts.
- Industrial sewing machine operations
- Quality checks at each sewing stage
- Overlay and flatlock capabilities
- Specialized equipment for different garment types
Printing, Embroidery & Finishing
We offer comprehensive customization services including screen printing, DTG printing, embroidery, applique, and various washing effects. Your brand elements are applied according to your placement specifications. Washing and finishing processes add desired effects and softness.
- Screen printing and digital printing
- Embroidery and applique application
- Washing processes (stone, acid, vintage effects)
- Heat pressing and other finishing techniques
Quality Control & Inspection
Every garment undergoes thorough quality inspection. We check measurements, stitching quality, print/embroidery placement, fabric defects, and overall construction. Only garments that meet specifications proceed to packaging. Defective items are repaired or reproduced.
- Individual garment measurement checks
- Stitching and construction inspection
- Print and embroidery quality verification
- Final approval before packaging
Labeling, Packaging & Export
Approved garments receive your custom neck labels, care labels, and hang tags. Items are folded and packed in poly bags or your specified packaging. We prepare complete export documentation and coordinate shipping to your destination. Our logistics team ensures proper customs compliance.
- Custom label and hang tag application
- Individual poly bag packaging
- Master carton packing with labeling
- Export documentation and shipping coordination
Manufacturing Capabilities
Comprehensive services and options available throughout the production process.
Fabric Options
- 100% cotton (various GSM: 150-400)
- Cotton-polyester blends
- French terry and fleece
- Denim (10-14 oz, stretch options)
- Technical and performance fabrics
Customization Services
- Screen printing & DTG printing
- Embroidery & applique
- Puff print & specialty prints
- Washing effects & distressing
- Custom labels & packaging
Quality Checkpoints
- Fabric inspection upon arrival
- Cut piece verification
- In-line sewing quality checks
- Post-production inspection
- Final QC before packaging
Frequently Asked Questions
How long does the complete manufacturing process take?
From approved tech pack to finished goods ready to ship, the typical timeline is 20-30 days. This includes 7-10 days for sampling, 3-5 days for sample approval and revisions, and 15-20 days for bulk production. Rush orders can be accommodated with adjusted timelines.
Can I customize the manufacturing process for my order?
Yes, absolutely! We offer flexible production options. You can specify custom washing treatments, special finishing techniques, unique packaging requirements, or additional quality checkpoints. Our production team will work with you to implement any customizations that align with your brand requirements.
What quality control checks are performed during production?
We implement AQL 2.5 inspection standards with multiple checkpoints: fabric inspection upon receipt (4-point system), in-line quality checks during production, pre-final inspection before packaging, and final random inspection before shipment. Each garment is checked for stitching quality, measurements, printing/embroidery accuracy, and overall finish.
Do you provide samples before bulk production?
Yes, sampling is a mandatory step in our process. We create pre-production samples for approval before starting bulk manufacturing. Sample fees are $30-50 per style (refundable with bulk order). You'll receive physical samples via DHL/FedEx within 7-10 days for evaluation and approval.
What file formats do you accept for tech packs?
We accept PDF, AI (Adobe Illustrator), EPS, and CDR (CorelDRAW) files for tech packs. For artwork and graphics, we prefer vector formats (AI, EPS, PDF) for best quality. High-resolution raster images (PNG, JPEG at 300 DPI minimum) are also acceptable. If you don't have a tech pack, our design team can help create one from your sketches or references.
Can I visit the factory during production?
Factory visits during production are welcome! This allows you to see your order in progress, meet our production team, and verify quality firsthand. We recommend scheduling visits during key production stages (cutting, sewing, or final inspection). Please contact us at least 1 week in advance to arrange a visit.
Our Production Track Record
Real performance metrics from our manufacturing operations
Monthly Production
Across all product categories and fabric types
On-Time Delivery
Consistently meeting agreed production deadlines
Days Lead Time
From order confirmation to shipment ready
Defect Rate
AQL 2.5 standard inspection results
Success Story: From Startup to Established Brand
How we helped UrbanVibe scale their production
The Challenge
UrbanVibe, a sustainable streetwear startup from California, needed a reliable manufacturer who could support their growth from small test batches to full production runs. They required flexibility in MOQ, consistent quality, and fast turnaround times.
Our Solution
- Started with MOQ of 150 pieces across 3 styles for market testing
- Provided detailed tech pack review and fabric recommendations
- Implemented streamlined approval process for faster sampling
- Maintained consistent 22-day lead times as volume increased
The Results
Timeline to scale from 150 to 5,000 pieces per order
Product line expansion with consistent quality across all items
In 8 consecutive shipments (40,000+ total pieces)
"Brosan Textile didn't just manufacture our products – they became a true partner in our growth. Their flexibility with MOQ and consistent quality allowed us to test and scale confidently."
Alex Martinez
Founder, UrbanVibe Apparel