Ensuring consistent color quality in garments is essential for meeting buyer specifications and maintaining brand standards. One of the most critical processes in garment manufacturing is the Shade Band Submission and Approval Procedure. This procedure ensures that the colors of fabrics and garments stay within the required shade range, preventing variations that could lead to rejection by buyers or customers.
In this article, we’ll explore what shade bands are, why they are important, and the step-by-step procedure for submitting and approving shade bands in a garment factory.
What is a Shade Band?
A Shade Band refers to a set of fabric color swatches representing the acceptable color range for finished garments. These swatches help ensure that the final products meet the buyer’s color requirements. The color range is typically evaluated against predefined standards to confirm that the fabric and finished garments match the required tones.
Why is Shade Band Needed?
The primary purpose of a shade band is to control color consistency throughout the production process. This includes ensuring that the fabric’s color remains consistent from roll to roll, lot to lot, and throughout various production stages. Proper shade band management is vital for the following reasons:
® Consistency: Helps maintain uniform color in mass production.
® Buyer Satisfaction: Meets the buyer's color expectations and minimizes rejections.
® Quality Assurance: Ensures that each garment or fabric batch is within the agreed-upon color standards.
Shade Band Submission Procedure in
Garment Factories
To ensure that the fabric’s shade remains within the approved color range, garment manufacturers follow a systematic procedure. Here’s a breakdown of the shade band submission procedure:
® Collection
of Fabric Swatches: During fabric inspection, swatches must be collected
from every roll and dye lot of both main and trim fabrics. Swatches should be
taken from the beginning and end of each fabric roll to show any color
variations. Each swatch should be labeled with the corresponding lot or roll
number for identification.
® Garment
Wash and Testing: The swatches should be sent to a washing factory to check
for any color changes after the washing process (which could affect the final
garment’s appearance). The swatches should be subjected to the same washing or
after-treatment processes that the final garments will undergo.
® Sorting
and Grouping of Swatches: The swatches are sorted based on color under
artificial light sources like TL84 and D65 light boxes to assess color
variations accurately. The swatches are then grouped into different shade lots
(e.g., A, B, C, D, E) based on their color proximity.
® Preparation
of Color Continuity Cards: A 15 cm by 15 cm cutting of each swatch should
be mounted on a Color Continuity Card. Each card should also include the
corresponding lot number and the total yardage of each dye lot. The Color
Continuity Cards are prepared in triplicate to ensure accurate tracking.
® Approval
Process: The buying house, along with the QC department or merchandisers,
must review the shade bands. Once agreed upon, the approval is signed off, and
one copy is sent back to the factory, one is sent to the wash factory, and one
remains with the buying house for future reference. The factory updates its
system with the approved shade details to ensure consistent shade
identification during production.
® Monitoring
and Control of Color Continuity: QC inspectors at various stages of
production monitor shade consistency by comparing the garments with the
approved color continuity card. If a garment's color falls outside the approved
shade band, the issue is reported to the factory, which works with the dyeing
mills to correct the variation.
® Final Color Evaluation: Garments undergo a final evaluation under the light box, with 1000 lux lighting conditions to verify that they meet the buyer’s color requirements. If the colors are acceptable, the garments proceed to the finishing stage; if not, they are sent back to the wash or dyeing factory for reprocessing.
Shade Control Procedure in Garment
Factories
Shade control is vital throughout the garment manufacturing process to ensure consistency from fabric production to the final garment. Here’s how shade control is typically maintained in woven garment production:
® Roll
Inspection and Documentation: During fabric inspection, it's crucial to
observe any shade variations in the fabric. Swatches are cut (approximately 6”
by 6”) from each roll and overlocked for documentation. Each roll should be
marked with its fabric lot, consignment number, and roll number to ensure
traceability.
® Shade
Segregation: The fabric is segregated into different shade lots (e.g.,
Shade A, Shade B, Shade C) using a lightbox and artificial light sources. The
factory creates distinct groups for each shade and marks the lot numbers
clearly.
® Fabric
Lay and Cutting Process: During the cutting process, the factory uses a lay
chart to ensure that the correct shade is placed in each garment. The first lay
will often be composed of the most predominant shade, followed by other shades
based on priority. After cutting, the bundles are labeled with the
corresponding shade number to prevent mix-ups.
® Garment
Sewing and Wash Process: Each sewing operator is instructed to attach the
corresponding shade label to each garment component (e.g., leg panels,
sleeves). During washing, the QC department must monitor and ensure that each
batch of garments is washed separately by shade to avoid mixing shades.
® Final Shade Inspection: Once the garments
return from the wash process, a final shade inspection is carried out. If the
colors meet the approved standards, they move forward to finishing; otherwise,
they are sent back for reprocessing.
® Packaging and Shipping: The final garments are packed according to their shade groups. Shade-wise packing helps prevent any mix-up during shipping and ensures that buyers receive consistent color products.
Importance of Shade Control in Garment
Manufacturing
Proper shade control is crucial for maintaining color consistency and meeting buyer expectations. If shade variations are not controlled, it can result in:
® Short Shipments: If garments don’t match the approved shade, the buyer may reject the order.
® Increased Costs: Reworking garments or reprocessing fabric to correct shade variations can incur additional costs.
® Customer Disappointment: End customers may reject garments if there is a noticeable color difference, leading to poor brand reputation.
Finally, Shade band submission and approval procedures play a vital role in ensuring color consistency throughout the garment manufacturing process. By adhering to these detailed procedures and maintaining strict shade control measures, garment manufacturers can meet buyer expectations, reduce the risk of rejection, and improve overall product quality.
By following this process, garment factories not only ensure high-quality products but also build trust with their buyers, creating long-term business relationships. If you have any questions or need further clarification on shade band procedures, feel free to ask us for more details.
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