Full Production Cycle
Clothing Production in Portugal
White Cotton runs a complete clothing production line in Barcelos, Portugal — from raw fabric to finished, packaged garments. Every stage happens under one roof: fabric sourcing, cutting, sewing, decoration, quality control, and packaging. We produce custom hoodies, t-shirts, sweatshirts, outerwear, shirts, and pants with a minimum order of 50 units per style.
4–6 Weeks
Production timeline
MOQ 50 Units
Per style & colour
In-House QC
4 checkpoint system
Barcelos
Made in Portugal
From Fabric to Finished Garment
The Production Process
Clothing production is the full sequence of steps that transforms raw fabric into a finished, labelled, packaged garment ready for sale. At White Cotton, every step in this sequence happens inside our own facility in Barcelos — we do not outsource cutting, sewing, or finishing to third parties. This gives us direct control over quality, timelines, and costs at every stage.
Our production process runs in six stages: fabric sourcing and inspection, pattern grading and cutting, sewing and assembly, decoration (embroidery, printing, labels), quality control, and finishing with packaging. Each stage has its own quality checkpoint — we catch problems inline rather than discovering them at the end when they are expensive to fix.
A typical production run takes 4–6 weeks from sample approval to delivery. Simpler garments like t-shirts move through faster; complex items with multiple decoration techniques or heavyweight fabrics take longer. We run multiple production lines in parallel, so different styles can be in production simultaneously without delays.
What sets our production apart is transparency. You receive updates at each stage — when fabric arrives, when cutting starts, when sewing is complete, and when your order ships. If something needs your attention (a colour variance, a measurement question), we flag it immediately rather than making assumptions. You always know where your order stands.
Six-Stage Workflow
Production Stages
Fabric Sourcing & Inspection
We source fabrics from certified European mills or work with your supplied materials. Every roll is inspected on arrival — we check weight, colour consistency, weave quality, and test for defects before a single cut is made.
Pattern Grading & Cutting
Patterns are graded across your full size range and arranged into markers for maximum fabric efficiency. Cutting is done by experienced operators who verify grain alignment and pattern accuracy on every layer.
Sewing & Assembly
Cut panels move to the sewing floor where operators assemble each garment following your approved sample. We run inline quality checks during sewing — stitch density, seam strength, and measurements are verified at the line, not just at the end.
Decoration
Embroidery, printing, labels, and other decoration techniques are applied after sewing. Placement is verified against your tech pack specifications. We check every decorated garment for alignment, colour accuracy, and finish quality before it moves forward.
Quality Control
Every garment goes through final QC — full measurement check against your size chart (±1 cm tolerance), visual inspection for defects, thread trimming, and verification of labels, tags, and packaging requirements. Failed units are reworked or replaced.
Finishing & Packaging
Garments are pressed or steamed, folded to your specifications, poly-bagged with size stickers, and packed into shipping cartons. We include packing lists and can apply custom packaging, tissue paper, stickers, or hang tags as needed. Ready-to-ship or ready-for-retail.
Quality Assurance
Quality Control Checkpoints
Quality control is not a single step at the end of our production line — it is built into every stage. We run four dedicated checkpoints during each production run, plus continuous inline monitoring by our sewing supervisors. This approach catches defects early, when they can be corrected in seconds rather than requiring full rework.
Our measurement tolerance is ±1 cm on key points (chest, length, sleeve). Every garment in the order is measured at final audit — we do not rely on random sampling. If a garment falls outside tolerance, it is reworked or replaced from our buffer stock (we cut 2–3% extra on every order for exactly this purpose).
Fabric Inspection
Weight, colour, defect testing
Post-Cut Verification
Pattern & grain accuracy
Inline Sewing QC
Stitch, seam & measurement
Final Audit
Full inspection before packing
Timeline Breakdown
Production Timeline
Understanding the production timeline helps you plan collection launches and manage inventory. Here is a realistic breakdown of how long each phase takes for a standard order of 200–500 units:
1–2 weeks
Sampling
Pattern development, sample production, fit review, and revisions until approved.
1–2 weeks
Fabric Sourcing
Ordering and receiving fabric from mills. Can run in parallel with sampling if fabric is in stock.
1–2 days
Cutting
Pattern grading, marker making, and cutting the full order quantity.
1–3 weeks
Sewing
Assembly of all garments. Duration depends on style complexity and order size.
2–5 days
Decoration
Embroidery, printing, label application, and other finishing techniques.
2–3 days
QC & Packing
Final inspection, pressing, folding, poly-bagging, and carton packing.
Fabric Library
Fabrics Available for Production
Decoration in Production
Decoration & Finishing Techniques
Production Services
Full-Package Production Services
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White Label Manufacturing
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Custom Clothing Manufacturing
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Collection Development
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Common Questions
Frequently Asked Questions
How long does clothing production take?
A standard production run takes 4–6 weeks from sample approval to delivery. This includes fabric preparation (2–3 days), cutting (1–2 days), sewing (1–3 weeks depending on quantity and complexity), decoration (2–5 days), quality control (1–2 days), and packaging and shipping (2–3 days). Sampling before production takes an additional 1–2 weeks. For seasonal collections, we recommend placing orders 8–10 weeks in advance.
What is the production process from start to finish?
Our production process follows seven stages: (1) fabric sourcing and inspection, (2) pattern grading and marker making, (3) fabric cutting, (4) sewing and assembly, (5) decoration — embroidery, screen printing, DTG, or other techniques, (6) quality control and measurement checking, and (7) finishing, pressing, folding, labelling, and packaging. Each garment passes through every stage in sequence, and we run inline quality checks between stages — not just at the end.
What quality checks happen during production?
We run quality control at four points: incoming fabric inspection (weight, colour, defects), post-cutting verification (pattern accuracy, grain alignment), inline sewing checks (stitch count, seam strength, measurement tolerances), and final audit before packaging (appearance, labelling, size accuracy). Our tolerance is ±1 cm on key measurements. Any garment that fails inspection is reworked or rejected — we do not ship defective units.
Can I visit during production?
Yes — factory visits are available for production clients. Once your samples are approved and bulk production is confirmed or underway, we arrange a full tour of our cutting, sewing, and finishing departments. You can see your order on the production floor. Our facility is in Barcelos, about 45 minutes from Porto airport.
What happens if there is a defect in production?
Defects caught during inline inspection are reworked immediately — the garment goes back to the relevant station for correction. If a defect is found at final QC that cannot be reworked (fabric flaw, irreversible stain, structural issue), the unit is rejected and replaced from extra units we cut as buffer (typically 2–3% over the order quantity). If a defect is discovered after delivery, we offer replacement production at no additional cost for manufacturing faults.
What is your production capacity?
Our facility handles 3,000–5,000 units per month across all garment types. We run multiple production lines simultaneously, so we can produce different styles in parallel. For larger orders (1,000+ units of a single style), we dedicate a full line to maximise efficiency and consistency. Our minimum order quantity is 50 units per style and colour, making us accessible to both emerging brands and established labels.
Do you handle fabric sourcing as part of production?
Yes. Our full-package production includes fabric sourcing from trusted European mills. We maintain a library of 15+ fabric types — organic cotton, French terry, fleece, sherpa, corduroy, denim, and more — in weights from 180 to 1100 GSM. If you have a specific fabric supplier, we also work with client-supplied materials. Fabric is inspected on arrival before entering the production line.
What decoration techniques are available during production?
We offer embroidery (flat, 3D puff, chenille, chain stitch), screen printing (plastisol, water-based, discharge, puff), DTG (direct-to-garment digital printing), DTF transfers, sublimation, heat transfers, woven labels, printed labels, hang tags, and custom packaging. Decoration is integrated into the production line — it happens after sewing and before final QC, so every decorated garment is inspected for placement accuracy and finish quality.
Ready to Start Production?
Send us your designs and get a detailed production quotation within 48 hours.
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