Quality Control in Turkey Clothing Manufacturing
Comprehensive quality assurance processes that protect your brand reputation and ensure consistent garment quality across all production runs.
Quality Assurance Key Points
AQL 2.5 Standard
International sampling methodology with max 2.5% defect acceptance
5-Stage Inspection
From fabric arrival to final shipment approval checkpoints
Full Documentation
Detailed inspection reports with photos and measurements
Quality control is the foundation of successful private label clothing manufacturing. At Brosan Textile, we implement systematic quality inspection procedures at every production stage—from incoming fabric inspection to final pre-shipment verification. Our quality team uses AQL 2.5 sampling standards and documented inspection protocols to ensure your garments meet specifications consistently.
For B2B brands, quality inconsistencies create customer returns, damage brand reputation, and increase operational costs. Our multi-stage quality control system identifies defects early, maintains production standards, and provides transparency through detailed inspection reports. This approach protects your brand while minimizing production delays.
We understand that quality requirements vary by market and brand positioning. Whether you need basic commercial standards or premium quality benchmarks, our inspection processes adapt to your specifications while maintaining efficient production timelines.
Our Five-Stage Quality Control Process
Systematic inspection checkpoints throughout production ensure defects are caught early and corrected before they become costly problems.
Incoming Fabric Inspection
Before cutting begins, we inspect all incoming fabrics for defects, color consistency, weight accuracy (GSM), and dimensional stability. Our fabric inspection team examines fabric rolls using standardized 4-point system inspection on illuminated tables. We verify that fabric specifications match your tech pack requirements including composition, weight, width, and color standards.
Common fabric defects we identify include color variation, holes, stains, slubs, wrong patterns, GSM deviations, and shrinkage issues. Fabrics that fail inspection criteria are rejected before production begins, preventing defective materials from entering your garments.
What We Check:
- Fabric weight (GSM) verification with scale testing
- Color matching against approved lab dips or standards
- Surface defects: holes, stains, slubs, wrong patterns
- Width and shrinkage testing for dimensional stability
- Fabric hand feel and drape quality assessment
Cutting and Pattern Verification
After fabric approval, cutting room quality control verifies pattern accuracy, marker efficiency, and cutting precision. We inspect first cut pieces against pattern specifications to confirm measurements match your tech pack before bulk cutting proceeds. This checkpoint prevents systematic sizing errors that would affect the entire production run.
Our cutting team uses automated cutting machines with CAD pattern systems for accuracy. Quality inspectors verify that cut pieces maintain correct dimensions, grain alignment, and pattern matching for prints or stripes. We also monitor fabric utilization to ensure efficient marker making without compromising garment quality.
In-Line Production Inspection
During sewing, our quality inspectors conduct in-line checks at each production stage. This includes verifying stitch quality, seam strength, construction methods, attachment accuracy, and overall workmanship. In-line inspection catches defects while garments are still in production, allowing immediate correction before defective units accumulate.
We inspect specific checkpoints including collar attachment, sleeve setting, side seam straightness, hem quality, buttonhole placement, zipper functionality, and pocket construction. Each operator's work is periodically checked to maintain consistent quality across all production lines.
Production Checkpoints:
- Stitch density and tension (SPI - stitches per inch)
- Seam strength and construction method verification
- Thread color matching and thread type compliance
- Trim and accessory attachment quality
- Print registration and embroidery quality
Post-Production Finishing Inspection
After sewing completion and washing (if applicable), garments undergo detailed finishing inspection. This stage verifies washing results, pressing quality, trim attachment, label placement, and overall appearance. We check that garments emerge from finishing processes in sellable condition without damage or defects introduced during post-production handling.
For washed garments, we verify wash effects match approved samples, shrinkage remains within tolerance, and no color bleeding or fabric damage occurred. Labels, hangtags, and packaging materials are inspected for accuracy, placement, and attachment quality before final inspection begins.
Final AQL Inspection and Shipment Approval
Before shipment authorization, we conduct comprehensive final inspection using AQL 2.5 sampling methodology. Our quality team randomly selects garments from completed production, conducting detailed examination against your specifications. This inspection verifies measurements, construction quality, appearance, functionality, and packaging compliance.
AQL 2.5 (Acceptable Quality Limit) means we accept a maximum of 2.5% defective garments in the production lot. Our inspection determines if the batch passes, requires rework, or fails based on critical, major, and minor defects found during sampling. Only production that meets AQL standards receives shipment approval.
Final Inspection Includes:
- Complete measurement verification across all size runs
- Visual inspection for defects, stains, and damage
- Functionality testing: zippers, buttons, snaps, drawstrings
- Label and packaging accuracy verification
- Carton packing, quantity count, and shipping mark confirmation
Understanding AQL 2.5 Standards
AQL (Acceptable Quality Limit) 2.5 is an international sampling standard used throughout the garment industry to determine production acceptance or rejection. Rather than inspecting every single garment, AQL uses statistical sampling to assess overall production quality efficiently.
The inspection categorizes defects into three levels: critical defects (garment unusable), major defects (significantly reduce usability or salability), and minor defects (small imperfections that don't affect function). AQL 2.5 means we accept up to 2.5% major defects in the sampled quantity.
For example, in a production of 1,000 garments, we randomly select and inspect 80 pieces according to AQL tables. If we find more than 5 major defects or any critical defects in this sample, the entire lot fails inspection and requires rework or rejection.
Defect Classification Examples
Critical Defects
- • Broken or non-functional zippers
- • Wrong size labels
- • Holes or tears in fabric
- • Completely wrong colors
- • Missing components
Major Defects
- • Loose or skipped stitches
- • Visible stains or marks
- • Print misalignment
- • Measurement deviations outside tolerance
- • Uneven dyeing or color shading
Minor Defects
- • Small thread ends not trimmed
- • Slight puckering at seams
- • Small wrinkles after pressing
- • Minor label placement variations
- • Slight shade variations within tolerance
Quality Documentation and Reporting
Transparent quality records provide traceability and accountability throughout your production.
Inspection Reports
Detailed inspection reports at each quality checkpoint document findings, defect rates, and corrective actions. Reports include photos of defects found and statistical analysis of quality performance.
Measurement Sheets
Complete measurement verification records showing actual measurements versus tech pack specifications across all size runs. Tolerance compliance is documented for every measurement point.
Test Certificates
Fabric test reports and compliance certificates available upon request. Testing includes colorfastness, shrinkage, pilling resistance, and other standard garment tests as required.
Third-Party Inspection Services
We welcome and accommodate third-party inspection agencies for clients who require independent quality verification. Common inspection companies we work with include SGS, Bureau Veritas, Intertek, and TÜV. We provide full access to production facilities, documentation, and sample selection to facilitate thorough independent inspections.
Third-party inspections typically occur at final inspection stage before shipment. We coordinate inspection scheduling and provide necessary production information to inspection agencies. Independent inspection reports supplement our internal quality documentation, providing additional assurance for your brand.
Frequently Asked Questions
What is AQL 2.5 quality standard?
AQL 2.5 means we accept maximum 2.5% major defects in sampled quantity. We inspect using statistical sampling (e.g., 80 pieces from 1,000 units). If more than 5 major defects found, the batch fails and requires rework. Critical defects (broken zippers, wrong labels, holes) = zero tolerance.
How many inspection stages do you have?
5-stage quality control: 1) Incoming fabric inspection (4-point system, GSM verification), 2) Cutting/pattern verification, 3) In-line production inspection (stitch quality, seam strength), 4) Post-production finishing (washing results, labels), 5) Final AQL inspection before shipment.
Can I arrange third-party inspection?
Yes, we fully accommodate SGS, Bureau Veritas, Intertek, or any inspection agency you prefer. You arrange and pay inspector directly. We provide facility access, documentation, sample selection. Inspections typically occur at final stage before shipment. 1-week advance notice recommended.
Our Quality Performance Data
Real inspection results from the past 12 months
Average Defect Rate
Measured across 2.4M pieces inspected
AQL 2.5 Compliance
All shipments meet or exceed standards
First-Time Pass Rate
Production approved without rework
Quality Checkpoints
Throughout the production process
Defect Distribution Breakdown
Common Issues (When They Occur)
Our Response System
- Immediate line stoppage for critical defects
- 100% rework or replacement for rejected items
- Root cause analysis within 24 hours
- Process adjustments to prevent recurrence
- Detailed documentation for client transparency
What Clients Say About Our Quality
Verified feedback from brands we manufacture for
"The quality control process at Brosan is impressive. We've received 12 consecutive shipments with zero defects. Their attention to detail and multi-stage inspection gives us complete confidence."
Rachel Thompson
Quality Manager, Nordic Apparel (Sweden)
"After issues with our previous manufacturer, Brosan's AQL 2.5 standard and transparent inspection reports were exactly what we needed. Customer returns dropped by 85% after switching."
David Park
COO, FitZone Athletics (USA)
"The detailed inspection photos and reports they provide before shipment are invaluable. We can approve remotely with confidence. No other manufacturer we've worked with is this thorough."
Isabella Romano
Head of Production, Bella Moda (Italy)