Your workwear protects you every day against hazards on the work floor. But it is also a great way of expressing your company identity: by using features such as specific details and colour combinations, it becomes a unique item. Sounds like a good idea? Then read this blog, which sets out the various steps in the selection process and their impact on price, lead times and so on.
How is a clothing item created and which parties are involved in this process? We will take you behind the scenes of the captivating clothing production process. We will explain the various steps, departing from the end product, i.e. the finished item, and working back to the start.
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Step 6: Clothing manufacturer
The final phase involves the actual creation of the clothing item by the clothing manufacturer or creator. The various components of the item, such as the cut pieces of fabric, zips, buttons, labels, etc. are all combined. Other finishing techniques, such as ironing, adding logos and so on, are used to give the item the desired look and fit.
This process is automated as far as possible and this means a minimum run is mandatory. An order for large quantities often means a discount.
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Step 5: Pattern design and cutting
Before the clothing is produced, patterns are made for the items, based on the design requirements. These patterns serve as the blueprint for cutting the fabric. The fabric is cut precisely to fulfil the specific requirements regarding the risks the clothing will face. Comfort and look are defined here too. This could include classic tailoring or a slim fit, additions such as pockets, a ladies cut and so on.
A new pattern must be made to accommodate any changes to the existing model. This then becomes a new product, with a new certificate.
Step 4: Textile or fabric production
Prior to making the patterns, the necessary fabric (textile) is produced. The weaving mill creates fabrics using a range of techniques. The choice of threads and the weaving process determine the weight and composition of the fabric. This has a huge impact on the degree of protection offered, and the clothing item's level of comfort and durability. The fabric can be dyed by the yarn producer or it may be dyed as a complete fabric.
Tip: You are advised to choose a colour that is produced as standard by the weaving mill. If you choose a customised colour, you must order a huge quantity of fabric in one go.
Depending on the supplier, the minimum purchase may be 100, 300 or even 1500 metres. Given that 2.5m is needed for a pair of trousers, or 2m for a work jacket, you can imagine how many clothing items you are signing up for in this instance.
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Step 3: Yarn production - spinning mill
The raw fibres are supplied to a spinning mill, where they are turned into yarn. Fibre processing involves cleaning, combing, carding and spinning the raw fibres to create fine yarns so they are ready for further processing. This yarn is then turned onto bobbins, which provide the basis for further processing.
Natural fibres such as cotton and wool also undergo a purification process to remove impurities and seeds.
Step 2: Fibre production
Fibres may be natural (cotton, wool and silk) or synthetic (polyester, nylon). The fibre options are chosen on the basis of the required characteristics for various working sectors, e.g. cotton for breathability, or synthetic fibres for water-repellent qualities. Synthetic fibres undergo chemical processes to turn polymers into fibres for further processing.
The fibres are then dyed at dying facilities before they are turned into yarns or fabrics. The colour of the clothing can be added to the fibres, yarns or the finished fabrics. When it comes to workwear, the fibre or the fabric is usually dyed.
Tip: Coloured fibres retain their colour better than coloured fabrics.
Step 1: Risk-analysis
The most important phase is the first: identifying the risks for which the clothing must offer protection. You must have assessed the risks before you can begin to select the fabric you would like to use for the clothing item and the design you will apply.
Conclusion
Clothing manufacturers have a fixed range of standard designs and fabrics. These choices are based on the most important applications and customer demand.
When we talk of a standard product, this concerns the combination of the design and the fabric from which it is made. These products cannot usually be modified (or only very slightly). Changes to standard items, such as adding extra pockets or other materials, are limited due to:
- Production locations: Returning for small alterations is not cost-efficient. Production generally occurs outside Belgium or the Netherlands, in countries such as Tunisia, Eastern Europe or Asia.
- Certification requirements: Safety standards must be maintained. Materials used for PPE must fulfil certifications. Additions may impact upon these safety standards.
- The existing collaborations with the weaving mill: every manufacturer or designer works with a set fabric producer or weaving facility. These weaving facilities also have their standard products in the form of fixed combinations of fibres, colours, thicknesses and techniques. For this reason, a clothing manufacturer cannot always offer alternative fabrics. Another colour or technique may be possible but this may involve long lead times and orders for large quantities.
The time- and cost-effective approach is to opt for a standard article and colours. Although the production process (the six steps) remains the same, any alterations or changes may significantly alter the production and the lead time.
For example, a request for an extra pocket could require a new production process. This takes 12 weeks, and that’s without shipment, which is often by sea, and the certification process for the new model.
An integrated project approach
Yes, you are right, there are many elements involved in manufacturing high quality workwear. Expert advice and clear communication are crucial throughout the process, which involves various different parties.
Vandeputte, as a distributor, works with various clothing manufacturers and can provide advice about the choice of the most suitable fabric and clothing manufacturer to meet your needs, right from the risk analysis. After production, we can also guide you through setting up the best logistics processes for subsequent orders, printing, maintenance and the repair of your clothing.
Make an appointment to discuss your clothing requirements
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