How to Choose the Right Fabric for Your Clothing Line Bangladesh Production Quality
Choosing the right fabric is the foundation of every successful clothing line. The wrong fabric choice can lead to poor quality, customer complaints, and costly returns. This guide will help you make informed fabric decisions for your clothing brand.
💡 Key Takeaway:
Fabric typically accounts for 40-60% of your garment cost. Choosing the right fabric affects quality, durability, customer satisfaction, and your brand reputation. Invest time in fabric selection—it pays off.
Understanding Fabric Types
1. Cotton
Best for: T-shirts, casual wear, everyday clothing
Properties: Breathable, soft, natural, durable
GSM Range: 140-220gsm (t-shirts), 180-250gsm (hoodies)
Cost: $2-4 per meter (depending on quality)
- 100% Cotton: Most breathable, natural feel, may shrink
- Cotton Blend (60/40): More durable, less shrinkage, better shape retention
- Organic Cotton: Eco-friendly, GOTS certified, premium pricing
2. Polyester
Best for: Activewear, performance wear, budget-friendly options
Properties: Moisture-wicking, quick-dry, wrinkle-resistant
GSM Range: 150-200gsm
Cost: $1-3 per meter
3. Poly-Cotton Blend
Best for: Workwear, uniforms, durable everyday clothing
Properties: Combines cotton comfort with polyester durability
Common Ratios: 65/35, 50/50, 60/40
Cost: $1.50-3.50 per meter
4. Denim
Best for: Jeans, jackets, casual pants
Properties: Durable, versatile, classic look
Weight: 10-14 oz (lightweight to heavyweight)
Cost: $3-8 per meter
5. Modal/Bamboo
Best for: Premium basics, underwear, soft garments
Properties: Ultra-soft, breathable, eco-friendly
GSM Range: 150-180gsm
Cost: $3-6 per meter
Understanding GSM (Grams Per Square Meter)
Stage 1: Fabric Inspection (Before Cutting)
When: As soon as fabric arrives at the factory
Why: Catch defects BEFORE cutting (once cut, fabric is wasted if defective)
What We Check:
- Color accuracy: Compare to approved lab dip or Pantone
- Fabric weight: Verify GSM matches order (180gsm, not 160gsm)
- Width & shrinkage: Test wash shrinkage rate
- Surface defects: Holes, snags, color streaks, pilling
- Hand feel: Softness and texture match sample
- Quantity: Ordered 2,000m, received 2,000m (not 1,800m)
🧵 Real Example:
Client ordered 180gsm cotton. Fabric arrived at 165gsm. Caught during inspection = fabric rejected and replaced. If not caught? 3,000 t-shirts would've been thinner than expected—bad reviews and returns inevitable.
Stage 2: During Production Inspection (DPI)
When: When 30-50% of production is complete
Why: Catch systematic errors early (before all 1,000 pieces are made wrong)
What We Check:
- Measurements: Compare finished samples to tech pack (chest, length, sleeve)
- Stitching quality: Straight seams, no loose threads
- Construction: Seam allowances, hem widths, collar shape
- Print/embroidery placement: Centered, correct size
- Trims & accessories: Correct buttons, zippers, labels
- Color consistency: All pieces same shade (no batch variation)
✅ DPI Success Story:
During-production check found chest width 2cm narrower than spec. Caught at 40% production = 400 pieces remade. If caught at final inspection? 1,000 pieces would've been wrong—€4,500 wasted.
Stage 3: Pre-Shipment Inspection (PSI) / Final AQL
When: When 100% of order is finished and packed
Why: Final check before shipping—your last chance to reject defects
What We Check:
- AQL sampling: Inspect statistically valid sample (explained below)
- Defect classification: Critical / Major / Minor
- Packaging: Correct poly bags, carton labeling, barcodes
- Quantity verification: Count pieces per carton, total cartons
- Accessories: Hangtags, care labels, size stickers attached
- Shipping marks: Correct address, PO number, SKU codes
Decision Point: Pass = approve shipment. Fail = re-work or reject batch.
Understanding AQL (Acceptable Quality Limit)
AQL is the international standard for garment quality inspection. It defines:
- How many pieces to inspect (sample size)
- How many defects are acceptable (pass/fail threshold)
AQL Levels Explained:
| AQL Level | Defect Rate | Typical Use |
| AQL 0.65 | 0.65% defects OK | Luxury brands |
| AQL 1.5 | 1.5% defects OK | Premium brands |
| AQL 2.5 | 2.5% defects OK | Standard (most common) |
| AQL 4.0 | 4% defects OK | Budget/fast fashion |
SupplyCloth Standard: We use AQL 2.5 by default, which means:
- ✓ Allows 2.5% minor defects (25 out of 1,000 pieces)
- ✓ Zero tolerance for critical defects (safety issues, wrong items)
- ✓ Minimal tolerance for major defects (unwearable flaws)
AQL Sampling: How Many Pieces We Inspect
AQL uses statistical sampling—we don't inspect every piece, but a representative sample:
| Order Size | Sample Size | % Inspected |
| 200-500 pcs | 50 pcs | 10-25% |
| 501-1,200 pcs | 80 pcs | 7-16% |
| 1,201-3,200 pcs | 125 pcs | 4-10% |
| 3,201-10,000 pcs | 200 pcs | 2-6% |
Defect Classification:
-
Critical Defects: Safety hazards or completely wrong items
- Example: Sharp needle left in garment, wrong product shipped
- Acceptable: 0 (instant fail)
-
Major Defects: Unwearable or significantly flawed
- Example: Holes, broken zippers, wrong size label, color mismatch
- Acceptable (AQL 2.5): Max 4 in sample of 125
-
Minor Defects: Cosmetic flaws that don't affect function
- Example: Loose thread, slight print imperfection, small stain
- Acceptable (AQL 2.5): Max 10 in sample of 125
Photo & Video Evidence: Real-Time Updates
Our Bangladesh team provides visual proof of inspections:
What You Receive:
- Fabric arrival photos: Fabric rolls, color comparison
- Lab test results: GSM, shrinkage, color fastness reports
- During-production photos: Sample pieces, measurements
- Pre-shipment video: Walkthrough of packed cartons
- AQL report with photos: Any defects found + severity classification
Why Visual Evidence Matters:
- ✓ Transparency: You see exactly what's happening
- ✓ Accountability: Factory knows we're documenting
- ✓ Dispute resolution: Photo proof if quality issues arise
- ✓ Peace of mind: Sleep well knowing production is monitored
📸 Real Example:
Client was nervous about their first Bangladesh order. We sent daily photos: fabric inspection ✅, first samples ✅, mid-production ✅, final packing ✅. Client felt in control despite being 8,000 km away.
The QC Timeline: When Inspections Happen
Typical Production Timeline with QC:
-
Week 1: Fabric arrives at factory
- → Fabric Inspection (Day 1-2)
- → Photos sent to you
- → Approve or reject fabric
-
Week 2-3: Cutting & sewing begins
- → During-Production Inspection (at 40% completion)
- → Photos of samples + measurements
- → Approve or request adjustments
-
Week 4-5: Production completes
- → Pre-Shipment AQL Inspection
- → Full AQL report with defect photos
- → Approve shipment or request rework
- Week 6: Shipment to Germany
What Happens If Inspection Fails?
Option 1: Rework (Minor Issues)
If defects are fixable (loose threads, missing labels), factory corrects them:
- Factory re-works defective pieces
- We re-inspect after rework
- Timeline delay: 3-7 days
- Cost: Factory absorbs (included in original quote)
Option 2: Partial Rejection (Mixed Quality)
If some pieces pass and some fail:
- We separate good pieces from defective
- Ship good pieces immediately
- Factory produces replacement batch for rejected pieces
- Cost: Negotiated (usually factory pays for replacements)
Option 3: Full Rejection (Major Failure)
If entire batch fails (wrong fabric, wrong color, critical defects):
- We reject shipment on your behalf
- Factory must reproduce entire order
- Timeline delay: 4-6 weeks
- Cost: Factory pays (contractually obligated)
💡 Why This Matters:
Without QC, you discover defects AFTER shipping (8 weeks + €1,500 shipping cost). With QC, we catch and fix before shipping—saving time and money.
Common Quality Issues & How We Prevent Them
Issue 1: Color Mismatch
Problem: Fabric color doesn't match approved sample
Prevention:
- Lab dip approval before bulk fabric order
- Physical color swatch comparison during fabric inspection
- Lighting conditions standardized (D65 light box)
Issue 2: Sizing Inconsistency
Problem: "Medium" varies by 3cm across batch
Prevention:
- Tech pack with precise measurements
- Sample approval before bulk production
- During-production measurement checks (every 50 pieces)
Issue 3: Print Placement
Problem: Logo off-center or wrong size
Prevention:
- Print strike-off approval (test print)
- First-piece inspection before full run
- Random checks during production
Issue 4: Fabric Defects
Problem: Holes, pilling, thin spots
Prevention:
- 4-point fabric inspection system
- Reject fabric rolls with >40 points/100m²
- Factory uses defect-free fabric or replaces
DIY QC vs Professional QC: The Cost-Benefit Analysis
| Scenario | DIY QC | SupplyCloth QC |
| Who inspects? | Factory "self-checks" | Independent 3rd party |
| Conflict of interest? | Yes (they want to pass) | No (we work for you) |
| Cost | €0 upfront | Included in service |
| Defect rate | 15-30% | Under 3% |
| Hidden costs | €2,500+ in defects | €0 (caught early) |
Bottom line: Professional QC costs you nothing extra (included in SupplyCloth's service) but saves thousands in avoided defects.
Conclusion: Quality is Your Brand Reputation
One batch of defective products can destroy years of brand-building:
- Bad reviews on Amazon/social media
- High return rates (eating into profits)
- Retailer bans (major stores drop you)
- Customer trust lost (hard to rebuild)
With SupplyCloth's 3-stage QC:
- ✅ Fabric inspected before cutting (prevent waste)
- ✅ During-production checks (catch errors early)
- ✅ Pre-shipment AQL inspection (final guarantee)
- ✅ Photo/video evidence (full transparency)
- ✅ Under 3% defect rate (vs 15-30% without QC)
Quality control isn't an expense—it's insurance against disaster. Protect your brand with professional QC from day one.
Get Production with Professional QC Included
Fabric inspection → During-production checks → AQL audit → Photo updates. All included.
Start Quality-Controlled Production