Pre-Production
Pre-production is the initial and most crucial stage before starting bulk garment manufacturing. This phase involves all the essential preparations needed to ensure the final product meets the buyer’s expectations in terms of design, fit, quality, and delivery timeline. At ExploreTex, we take a structured and detail-oriented approach to make sure everything is planned and approved before mass production begins.
The process starts with a comprehensive review of the tech pack, which contains all the design details, measurements, and specifications provided by the buyer. If a tech pack is not available, our experienced team develops one based on the client’s requirements. This document acts as the foundation for the entire production process, leaving no room for errors or miscommunication.
Once the tech pack is finalized, we source the required fabrics, trims, and accessories from trusted suppliers to guarantee premium quality. Fabric sourcing is one of the most critical steps because it directly impacts the garment’s durability, comfort, and overall look. At ExploreTex, we ensure that all materials comply with the buyer’s standards and certifications if required.
Next, we conduct lab dips for color matching to achieve the exact shades requested by the buyer. Color consistency is vital, especially for large orders, and our quality control team uses advanced testing methods to ensure accuracy. Alongside this, we prepare necessary samples such as proto samples, fit samples, and pre-production (PP) samples. These samples are submitted to the buyer for approval before proceeding further. This step ensures the product design, fit, and aesthetics align perfectly with the brand’s vision.
We also perform fabric testing for shrinkage, color fastness, and dimensional stability. These tests help maintain consistent quality throughout production and prevent unexpected issues during bulk manufacturing. Our team carefully monitors every aspect to minimize risks and ensure smooth operations.
Once all approvals are received, we finalize the production plan. This includes scheduling the production timeline, allocating factory capacity, and assigning skilled personnel to specific tasks. A clear workflow is prepared to streamline each process, from cutting and sewing to finishing and packaging. By planning ahead, ExploreTex ensures on-time delivery without compromising quality
Bulk Production
Bulk production is the core phase where approved garments are manufactured at full scale according to the buyer’s confirmed specifications. At ExploreTex, once all pre-production approvals are in place, we begin the mass production process in our certified partner factories. We ensure all materials—fabrics, trims, prints, and labels—are ready and meet quality standards. Production is carried out with strict adherence to the approved tech pack, measurement charts, and design details. Our dedicated quality control (QC) teams monitor every step of production, from cutting and stitching to printing, embroidery, and final finishing, ensuring consistency and compliance. We maintain regular communication with buyers and provide production updates, photos, and videos to ensure transparency. Each order is handled with care to meet deadlines, maintain quality, and deliver excellence from the first piece to the last.
Quality Assurance
Quality Assurance (QA) is a vital part of our production process at ExploreTex, ensuring that every garment meets the highest standards of quality, consistency, and buyer expectations. Our QA process begins from the initial stages—inspecting raw materials like fabrics and trims—and continues throughout the entire production cycle. We implement multi-stage inspections, including inline quality checks during stitching and printing, as well as final inspections before packaging. Our experienced QC teams follow AQL (Acceptable Quality Limit) standards and detailed buyer guidelines to detect and prevent any defects in stitching, sizing, labeling, finishing, and overall appearance. We also perform random spot checks, fabric performance tests, and ensure compliance with safety and international standards. By maintaining strict quality control procedures and clear communication with our factories, ExploreTex™ guarantees that each product delivered is flawless, reliable, and ready for the global market.
Packaging
Packaging is the final step before shipping and plays a key role in product presentation, protection, and brand identity. At ExploreTex, we follow buyer-specific packaging instructions to ensure each product is packed precisely according to the approved layout. This includes folding, tagging, barcoding, inserting into polybags (biodegradable or standard as per request), and placing them into master cartons with clear labeling. We ensure that packaging materials meet sustainability preferences and international shipping standards. Our team double-checks quantity, size breakdowns, and carton details to avoid any mismatch or damage during transit. Proper packaging helps not only in preserving the garment’s quality but also in enhancing the unboxing experience for retail or end customers.
