From Prototype to Mass Production: The 7 Steps of Garment Manufacturing

Step 1: The Brief and Material Sourcing

Everything starts with a detailed brief: tech packs, sketches, reference samples, material specifications. At LOI Confection, the dedicated merchandising team analyzes each brief and proposes a development plan.

• Full Package: LOI Confection manages material sourcing from certified suppliers (GOTS for organic)
• CMT: The brand provides its own fabrics and accessories

The brief must include: measurements by size, colors, desired fabric type and weight, finishes (embroidery, screen printing), packaging, and target quantities. The more precise the brief, the faster the prototyping.

Step 2: Prototyping (15-20 days)

The sampling department creates the first prototype from the brief. This is a critical step: the prototype must perfectly embody the design while being suitable for industrial production.

1. Pattern makers translate the sketch into a digital pattern.
2. The workshop assembles the first sample.
3. The quality department checks measurements and finishes.
4. The piece is sent to the brand for approval.

Important note: LOI Confection does not limit the number of revisions. Each round trip takes 15-20 days, and the process continues until perfect validation. Production never starts with an approximate prototype.

Step 3: Grading and Placement

Once the prototype is approved, pattern makers perform the grading: creating the pattern in all required sizes. Each size is checked with a control sample (pre-production sample). The placement optimizes the layout of the pattern pieces on the fabric to minimize waste—a major economic and environmental issue (offcuts are upcycled).

Step 4: Cutting

The cutting workshop uses automatic cutting machines for large runs (millimeter precision). The fabric is spread into a lay (multiple superimposed layers), the placement is projected, and the cutting is performed. Each cut bundle is labeled and tracked to ensure traceability throughout production. For small runs, cutting is done manually with templates.

Step 5: Assembly and Value-Added Services

The cut pieces are distributed to the production lines. LOI Confection has:

• Workshop 1 (15 lines): medium and large runs, optimized pace
• Workshop 2 (4 lines): small runs, rapid model changeovers

The value-added services—hand embroidery, machine embroidery, smocking, screen printing—are performed either before assembly (on cut pieces) or after (on the finished product), depending on the technique. The hand embroidery workshop operates in parallel with the production line.

Step 6: Quality Control (AQL 2.5)

Quality control is integrated at each step and reinforced at the end of the line. The final inspection follows the AQL (Acceptable Quality Level) 2.5 standard:

• 100% visual inspection of pieces at the end of the line
• Dimensional control through statistical sampling
• Specific babywear tests: snap fastener strength, absence of small detachable parts, compliance with EN 14682
• Validation of colors and embroideries against the approved sample

Step 7: Finishing and Shipping

The finishing workshop handles ironing, labeling, folding, and packing according to each brand's specifications. The integrated transit office manages shipping—by sea (25-30 days to Europe) or air (2-3 days) for urgent needs. The AGOA/SADC free trade zone offers significant customs advantages.

Small Runs vs. Large Runs