Why production takes months
Short answer: Production takes months because yarn must be spun, fabric knitted and dyed, samples approved and goods shipped. Each stage waits for the one before, and none of them can be skipped.
Each stage waits for the last
A garment comes together in a long chain of stages. Yarn is spun, fabric is knitted and dyed, the model is approved, the piece is cut and sewn, and the goods are sent off. Each stage can only begin when the previous one is done, so the waiting times add up on top of each other.
The fabric does not exist in advance
The colour is ordered only when the order is certain. Knitting and dyeing fabric for an order typically takes four to eight weeks. So the fabric is not sitting ready on a shelf at the factory, and it cannot be rushed without colour and quality suffering.
Dyeing is a process of its own
Dyeing happens in baths where the fabric needs the right time and temperature, and afterwards it must be rinsed and dried. The colour is checked before the fabric may be used. All of this happens before a single seam is sewn, and it is one reason the time stretches.
The sample rounds come first
Before production can start, the model must be approved. That means two to three rounds, with the sample sent back and forth between factory and buyer. Each round takes weeks. Only once the sample is approved can fabric for the whole batch be ordered. See our bestsellers for men.
Cutting and sewing
When the fabric is ready, it is cut to the pattern and sewn together. The factory has many orders at once, and your order joins the queue. Sewing a whole batch takes time, and each garment is checked along the way, so faults are caught before the goods are packed.
Checks before dispatch
Before goods leave the factory, a selection is checked against the approved sample and the size chart. If faults turn up, the batch can be delayed while they are fixed. Checking costs time, but less than sending a faulty batch halfway round the world and discovering it there.
Transport is the last long stretch
Sea freight from Asia to Europe takes five to eight weeks. Air freight is faster but costs many times more, so it is used only when needed. After arrival, goods must clear customs and be driven to the warehouse before they can be sold. See also Zent and Copenhagen Bamboo.
Why winter clothes are ordered in spring
The order must be placed long before the season to arrive in time. Winter clothing is ordered in spring, and spring clothing in autumn. That sounds early, but add up fabric, samples, sewing and transport and there is little slack. If goods arrive too late, the season is often over.
What can be done faster
You can go faster with air freight and stocked fabrics, but it costs more and limits the choice. Stocked fabrics exist in only a few colours and qualities. For a collection with many models and colours there is no shortcut without giving up something else.
Frequently asked questions
How long is the total time
From approved model to goods in stock, half a year is common. The time depends on the fabric, the factory queue and whether goods travel by sea or by air.
Can it be done faster
Yes, with air freight and stocked fabrics, but that costs more and limits the choice. That is why most people take the slower route to keep the price down.
Is that why winter clothes are ordered in spring
Yes. The order must be placed long before the season to arrive in time, because fabric, samples, sewing and transport together take about half a year.
You can find the full range at Bamboo-Clothing.com.
