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 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.
Quality Control Frequently Asked Questions
What quality standard do you use for final inspection?
We use AQL 2.5 (Acceptable Quality Limit) as our standard final inspection methodology, which is the international garment industry standard. This means we accept a maximum of 2.5% major defects in the sampled quantity. We can adjust to stricter standards like AQL 1.5 or 1.0 if your brand requires tighter quality control, though this may impact pricing slightly due to increased inspection labor and potential higher rejection rates.
Can I visit the factory to observe quality control processes?
Yes, we welcome factory visits from clients and encourage you to observe our quality control processes firsthand. Many brands visit during pre-production sample approval or during bulk production to verify quality systems. We can arrange factory tours, production line observations, and quality checkpoint reviews. Contact us in advance to schedule your visit and we'll coordinate timing with your production schedule.
What happens if my order fails final inspection?
If production fails AQL inspection, we immediately halt shipment and implement corrective action. Depending on the defects found, we either rework affected garments, conduct 100% inspection to remove defective pieces, or in rare cases, reproduce the order. We identify root causes, document the failure, and present a corrective action plan before resuming production. The specific remedy depends on defect severity, quantity affected, and timeline constraints. We work transparently with you to resolve quality failures appropriately.
Do you provide quality inspection reports before shipment?
Yes, we provide comprehensive final inspection reports with every order before shipment. Reports include AQL sampling details, defect classifications found, measurement verification results, photos of production, and overall pass/fail status. We send inspection reports for your review and approval before releasing shipment. This documentation provides transparency and serves as quality record for your receiving team.
Can you arrange independent third-party inspection?
We fully accommodate third-party inspection services from agencies like SGS, Bureau Veritas, Intertek, or any inspection company you prefer. You arrange and pay for the independent inspection service directly, and we coordinate access, documentation, and sample selection. Third-party inspection typically occurs during final inspection stage. We provide all necessary production information and facility access to ensure thorough independent verification of quality standards.
How do you handle fabric quality issues during production?
Fabric quality problems discovered during incoming inspection are immediately communicated to you before cutting begins. If fabric fails our inspection criteria, we reject the material and request replacement from the supplier. For fabric issues discovered after cutting has started, we assess the severity and quantity affected, then present options: use alternative fabric if available, wait for replacement fabric, or proceed if defects are within acceptable limits. We never proceed with substandard fabric without your explicit approval and full disclosure of the issue.
What is your measurement tolerance policy?
Standard measurement tolerance is ±0.5 cm (±0.2 inches) for most measurements unless your tech pack specifies tighter tolerances. Critical measurements like total length and chest width typically have tighter tolerance of ±0.3 cm. We measure garments in relaxed state without stretching fabric. Measurement verification occurs at pre-production sample stage and again during final inspection across all size runs. If your brand requires tighter tolerances, specify this in your tech pack and we'll implement stricter measurement control protocols.
Do you test fabric properties like shrinkage and colorfastness?
We conduct basic fabric testing during incoming inspection including visual examination, weight verification, and dimensional stability checks. For comprehensive fabric testing like shrinkage rates, colorfastness, pilling resistance, tensile strength, and chemical compliance, we use accredited third-party testing laboratories. These detailed tests are typically conducted during development stage or upon your request. Testing costs are separate from production costs. Test certificates can be provided with each production lot if required by your quality standards or target market regulations.