Assurance
Inspected in, not just inspected at the end.
Most quality failures are not discovered at final inspection — they are created at fabric intake and multiplied down the line. Eco Vira runs eight documented control points, from 4-point roll inspection through inline checks, AQL sampling, measurement audits and needle detection to container loading. Every lot ships with an inspection record and defect photographs, not a promise.
Fabric & Trim Inspection
Every roll is inspected on a light table under the 4-point system before it is allowed to enter cutting. We verify GSM against the approved swatch, check width and shade continuity across the lot, confirm shrinkage and colourfastness from a test wash, and log defect points per hundred square yards. Trims, threads, zips and elastics are checked against the approved trim card at the same time. Catching a barré fault or a shade band at this stage costs metres of cloth; catching it after sewing costs the order.
Inline Inspection
Quality is built at the operation, not recovered at the end of it. A dedicated inline QC approves the first piece off every operation against the sealed sample, then re-checks at statistical intervals through the run, recording seam construction, stitch density, tension, trim placement and symmetry. When a measurement or a stitch begins to drift the line is stopped and the operator re-set immediately, so a defect affects a handful of pieces instead of a whole cutting lot. Traffic-light hourly boards keep the floor supervisor and the buyer looking at the same data.
Final Inspection
Finished garments are inspected against the approved reference for construction, workmanship, appearance and presentation under standardised D65 lighting. Inspectors check seam strength and stitch security, label position and legibility, print and embroidery registration, button and zip function, thread trimming, pressing, shading between panels, and overall hand-feel. Defects are classified as critical, major or minor and photographed against a reference card, so a report tells you exactly what was found rather than simply whether the lot passed.
AQL Sampling & Standards
Lot acceptance follows ANSI/ASQ Z1.4 single-sampling at General Inspection Level II. The acceptable quality limit is agreed in writing before bulk starts, sample size is drawn from the lot size, and the accept and reject numbers are printed on the inspection report alongside the actual defect count. A failed lot is 100% re-inspected, reworked and re-offered under the same plan rather than quietly shipped. Buyers running to a retail standard can nominate AQL 1.5 for majors and 2.5 for minors, or set separate limits by defect class.
Measurement Checking
Measurement control begins at pattern approval and continues to pack-out. Sample garments are measured at every point of measure on the graded spec sheet, tolerances are agreed with the buyer, and cut panels are audited against the marker before bundling. During finishing, a fixed percentage of every size and colourway is re-measured after wash and press, when relaxation and heat-set shrinkage actually show. Deviations are plotted by size so a grading error is separated from an operator error, and corrected at source.
Needle & Metal Detection
Every finished garment passes through a calibrated conveyor needle detector before it can be packed — no exceptions, including samples. Sensitivity is verified at the start of each shift, at every break and at the end of the shift using certified ferrous test cards, and the results are recorded in a signed log. Broken needles are recovered, matched and accounted for under a controlled needle-issue policy. Childrenswear, sleepwear and food-service orders additionally run through metal detection with a per-carton pass record.
Packing Inspection
At pack-out we verify the finished-goods presentation against your packing manual: folding method and dimensions, tissue and cardboard inserts, hanger and hook direction, polybag size and suffocation warning, hang tag and price ticket placement, barcode scan verification, size ratio per carton, carton dimensions and gross weight, and shipping mark accuracy. Cartons are weighed and cross-checked against the packing list before sealing, so what appears on the commercial invoice matches what is actually inside the box.
Container Inspection
Before stuffing, the container is inspected for structural integrity, cleanliness, odour, moisture ingress, light leaks and previous cargo residue, and rejected outright if it fails. Loading is photographed at intervals, desiccant is used on long ocean routes, and the seal number is recorded and shared with the buyer along with the load plan. The full pre-shipment file — inspection report, defect photographs, measurement data, needle-detection log and container photos — is issued before departure, not after arrival.
AQL levels
Acceptance agreed before bulk.
AQL 1.5
Premium retail and fault-intolerant programmes
Tightest limit we operate; larger sample draw and lower accept number, specified for department-store and licensed goods
AQL 2.5
Standard export quality — our default
General Inspection Level II under ANSI/ASQ Z1.4, the accepted benchmark for branded apparel worldwide
AQL 4.0
Promotional, workwear and non-critical orders
Relaxed acceptance for price-led programmes where function outweighs cosmetic perfection
- Inspection reports and defect photographs supplied with despatch.
- Third-party inspection (SGS, Intertek, BV) welcomed at any stage.
Tell us the retail standard you are supplying into and we will set the AQL plan, the tolerance table and the checkpoint frequency for your programme in writing before bulk begins — then report against it. Third-party inspection by SGS, Intertek or Bureau Veritas is welcomed at any stage, and your own QC team is free to sit on our floor during production.
Request a QC plan