Quality control on a small-batch order isn’t a certificate — it’s a sequence of hands-on checks done at specific points in the production timeline. This page walks through what those checks are, when they happen, and what gets photographed before anything ships.
On a small batch, a single bad unit is a much bigger problem than it would be on a 10,000-unit run. The defect rate that gets absorbed by a full container shows up as a customer complaint on a 100-piece order. That’s why the QC process here is built around physical inspection rather than statistical sampling.
Every batch — catalogue order or custom sourcing — goes through the same five steps below. Each step is documented with photos and signed off before the next one begins.
Before bulk production starts, a pre-production sample is photographed from multiple angles and sent for written approval. The sample that gets signed off becomes the reference — the golden sample — against which every later batch is judged.
What gets checked: material, finish, dimensions, colour against Pantone or reference, print or embroidery placement, packaging inserts.
Once bulk production is roughly 30–50% complete, an interim inspection is run while the line is still running. Catching a problem here is cheaper than catching it after the line finishes.
What gets checked: consistency of finish against the golden sample, function tests where applicable (zips, closures, electronics), random measurements.
Once production is finished and packed, but before the cartons leave the factory, every unit is opened and visually inspected. Photographs of the batch are taken at this stage.
What gets checked: one-by-one visual scan, count verification, packaging integrity, label accuracy, carton marks.
Custom labels, inner boxes, polybags and outer cartons are applied by hand under supervision. Each packing configuration is photographed once before the carton is sealed.
What gets checked: label content (SKU, batch, language), correct polybag sizes, dunnage, master carton marks matching the packing list.
Before the truck leaves the yard, each carton is weighed and the weight recorded against the packing list. The final carton photo set is shared alongside the shipping documents.
What gets checked: carton count, gross weight, marking legibility, document match (commercial invoice, packing list, any certificates).
The full QC photo set — typically 8 to 15 images per batch — is shared before shipment. The standard set includes:
If a defect is caught at any stage, the batch is held before moving to the next step. The buyer is informed with photos the same day, and the options are agreed in writing: rework, replace, discount, or accept with disclosure. Nothing ships without an explicit decision.
Question about a specific category? [email protected]
A sketch, a reference photo or a sentence is enough. Every quote comes back itemised, with QC and packing included.