How to inspect a hoodie batch before it goes on sale

The moment a batch of hoodies arrives from the workshop or the decorator is your last chance to stop a problem before it reaches a customer. Many founders open a few boxes, see that the hoodies look fine and put them on sale. The problems then appear in reviews: a size that comes up small, a crooked embroidery, a missing label. A simple quality check, done systematically, pays for itself from the very first batch.

How much to check: sampling

You do not need to inspect every hoodie in detail, but three pieces are not enough either. The industry uses statistical sampling plans (AQL) that set how many pieces are checked from a lot and how many defects are acceptable. For a small brand, a practical rule is:

• fully inspect at least 10% of the batch, spread across every size and colour;
• give every piece a quick visual check when unpacking, for obvious faults;
• if you find more defects than expected, extend the inspection to the whole batch.

Pull pieces from different cartons, not just the first one you open. Record results on a simple form that stays the same for every batch: style, colour, size, what you checked and what you found. After a few batches, the form shows which problems keep recurring with each supplier and where to push.

Measurements

Measure hoodies laid flat on a table, using the same method as the tech pack:

1. Chest width, armpit to armpit.
2. Body length, from the high point of the shoulder to the hem.
3. Sleeve length.
4. Waistband and cuff width, relaxed.
5. Hood dimensions.

Compare with the tolerances in the tech pack. A consistent deviation on one size points to a pattern problem; random deviations point to a sewing problem.

Workmanship: seams and finishing

Check both outside and inside:

• straight seams with no skipped stitches or open sections;
• trimmed thread ends;
• symmetry of the kangaroo pocket and hood;
• evenly attached rib with no waves or pleats;
• finished drawcord ends and secure eyelets;
• oil marks, chalk or marker traces.

Shade and fabric

Compare hoodies with each other and with the approved sample in daylight. Look out for:

• shade differences between body and sleeves, a sign that panels were cut from different lots;
• differences between the rib and the main fabric;
• holes, pulled threads or knitting faults;
• the appearance of the brushed back, which should be even.

Decoration

For printed or embroidered hoodies, check the position against the neckline and the centre of the chest, measured the same way on every size. Look for incomplete prints, misregistered colours, cracks, puckered embroidery or untrimmed jump stitches. Run a simple wash test on one or two pieces from the batch.

Labels and packaging

• the size label matches the measured size;
• the composition and care label is present and correct, in line with EU Regulation 1007/2011;
• the brand label is sewn straight and secure;
• the hoodie is folded and packed as instructed, with the correct outer label.

A wrongly labelled size is one of the most expensive defects, because it guarantees returns.

Classifying and handling defects

Sort defects into three levels: critical (unsaleable or unsafe), major (a visible fault likely to cause a return) and minor (details that do not affect wear). For each one, note the piece, take a photo and report it to the workshop or decorator the same week. Pieces with minor defects can often be fixed; major ones go back for rework under your original agreement.

Quality starts with the fabric

Many faults start with the fabric: shade variation, inconsistent width, distortion after washing. A stable fabric cuts rejects right from the cutting table. One example is our dark green french terry, 280 g, combed cotton with elastane and a brushed back: it keeps its shape after washing, and every lot is checked against the approved sample before delivery. For other weights, see the french terry family.

For short runs, fabric can be bought by the roll from stock with no minimum; for your own colours, from 150 kg per colour through a quote request.