CLIENT SUCCESS STORY
A 100% human-silk digital-printed dress shortened by 7-8 centimeters after being washed in 40℃ water.After numerous tests and process adjustments,The shrinkage rate of the new sample garment was ultimately controlled within 2%.This collaboration will start with 100 pieces for each model.The current monthly order volume is approximately 8,000 pieces.
1.Project Start
This project began in 2020.A customer from Florida, USA, contacted us through our website.We hope to develop a high-end 100% silk digital-printed dress.The first batch will produce 100 units for each model.It will be the responsibility of the Foreign Trade Department Manager Luna to follow up.
Before purchasing the bulk fabric for production,First, we will use the sample fabric to make the sample garment.The sample fabric was first sent to the washing factory for general washing and shaping.After returning to the factory, conduct the high-temperature shrinking treatment.
2.Issues encountered with the first sample garment.
The sample fabric was sent to the digital printing factory.The fabric is first subjected to double-sided sizing.Then it undergoes high-temperature drying and digital direct printing.After the printing is completed,The fabric is sent back to the factory for making sample garments.And send it to the customer for confirmation.
After receiving the sample garments, the customer conducted a 40℃ water washing test.The dress will be shortened by 7-8 centimeters after being washed.Local deformation also occurred.The customer is not only concerned about this sample garment.Rather, the same question arises - will the same problem occur in the bulk production?
3.How do we find the cause?
After receiving the feedback,Luna did not merely reply to the customer with,We will re-do the sample.She has been in constant contact with the clients.Record the results of each round of testing.Inform the customers of the identified issues and the subsequent handling methods promptly.
Our technical team re-tested the entire prototyping process.After numerous comparisons,We found that the problem did not lie in the size of the pattern.Rather, it is handled before the digital printing process.
The pre-printing double-sided sizing was insufficient.The drying temperature did not meet the requirements.The drying time was also insufficient.The fabric is not yet fully stable.So, when the customer carried out the 40℃ water washing process, severe shrinking occurred.
|
WASH TEST |
RESULT |
| Water Temperature | 40°C |
| Length Change | 7–8 cm |
| Sample Status | Not Approved |
4.Adjust the process and produce new samples.
After finding the cause,We will inform the client of the test results and the adjustment plan.Subsequently, we adjusted the amount of coating on both sides.Increase the drying temperature and extend the drying time.
After the digital direct injection is completed,The printed fabric was sent back to the factory for high-temperature shrinking and shaping.Then the pattern maker modifies the pattern according to the actual shrinkage rate.Our pattern makers modify the patterns according to the actual shrinkage rate.And remake the sample garment.
After receiving the new sample garments, the customer conducted another water washing test.We are satisfied with the modified dimensions and the design.And received positive feedback.After obtaining the customer's confirmation,We have just purchased the bulk fabric.And began to produce the first batch of orders, each consisting of 100 units.
5. From 100 items to approximately 8,000 items per month
This collaboration allowed the client to observe our approach to handling problems:Identify the cause and maintain continuous communication.And address the risks before the bulk production begins.
From 2020 to 2026,The two parties have been cooperating for nearly six years.The customer visited Mengruolan Clothing Factory three times successively.The order quantity has also increased from 100 pieces per item initially to approximately 8,000 pieces per month currently.
|
NEARLY 6 YEARS |
3 FACTORY VISITS |
APPROX. 8,000 PCS/MONTH |
| Long-Term Partnership | In-Person Communication | Current Order Volume |
