Guide · March 30, 2026 · 15 min read
You have a collection design. How do you go from a sketch to thousands of perfectly identical pieces? Here is the complete 7-step textile manufacturing process as practiced at LOI Confection in Madagascar.
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.
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.
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.
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.
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).
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.
The cut pieces are distributed to the production lines. LOI Confection has:
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.
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:
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.
| Criterion | Small Runs (Workshop 2) | Large Runs (Workshop 1) |
|---|---|---|
| Quantity | 100-1,000 pcs | 1,000-10,000+ pcs |
| Lines | 4 dedicated lines | 15 lines |
| Flexibility | High | Medium |
| Unit cost | Higher | Optimized |
The complete process takes 10 to 16 weeks: 2-4 weeks for prototyping (with revisions), 1-2 weeks for grading/placement, 4-6 weeks for production, 1 week for finishing and packing. Sea freight to Europe adds another 4-5 weeks.
No. LOI Confection does not limit the number of prototype revisions and does not charge for them beyond the initial development cost. This is a quality guarantee: production never starts with an approximate prototype.
100 pieces per style. Workshop 2 (4 lines) is specifically designed for creative small runs of 100 to 1,000 pieces. Workshop 1 (15 lines) is optimized for volumes from 1,000 to 10,000+ pieces.
Yes, in Full Package mode. LOI Confection sources fabrics and accessories from certified suppliers (GOTS for organic). In CMT (Cut-Make-Trim) mode, the brand provides its own materials.
Quality control is integrated into each stage (in-process) and reinforced at the end of the line according to the AQL 2.5 standard. Requirements are stricter for baby clothing (snap fastener strength tests, absence of small detachable parts).