As a plush-making manufacturer in this traditional industry for years, we can deeply understand price should not be the only thing to consider if the supplier is qualified or not. The prices quoted were based on each factory’s internal operation costs, the lowest price doesn’t mean it’s the most suitable. Today we’d like to share our internal quality standard for bulk customized plush animals and merchandise. If you have further questions or need help with your custom-made plushies project, please get in touch with us.
Incoming fabrics check and cutting
- Check the fabric color is the same as the PP sample client signed back, weight/density is within the acceptable tolerance.
- Cut the swatches ( not small than 10 * 10cm size) to rub then soak in the water for 1 hour at least. Make sure no fade.
- Most fabrics were not allowed to exceed 8 layers when cutting. But materials like T/C and nylon such thin fabrics maximum was under 36 layers. Workers need to check the fur direction as per “instructions” and “PP sample”. Pieces with drawnwork must be discarded directly.
- After all the above, check the top layer and the bottom one to make sure the cutting mold wasn’t displaced and caused unnecessary mistakes.
Stitching process
Handmade stitching and sewing are the key processes in the production of plush toys, resulting in toys quality good or not directly. Each production department must operate strictly as per instructions here.
The edges of the two fabrics must be aligned, the sewing distance should not be less than 9 stitches per inch, and the quality of the thread must be in line with the tension. Make sure the “fur” on the hands and feet must be in the same direction. Sewn the label is firm enough and has no wrinkle. Any missing stitches or skipped stitches are totally unacceptable.
Plastic eyes & noses punching
The glitter eyes and plastic noses are so common for plush animal toys and even lifelike soft animals. When these plastic parts arrived, our staff will check all the parts to ensure no sharp edges, no scratches, and no damage. After these inspections and punching process, our QC team will need to inspect the “eyes” are horizontal and firm enough to pass the 21lbs stretching test.
Cotton stuffing
Our standard for the cotton filling was overall should be “full” and “soft”, focus on the soft toys’ head shape and the mouth should be firm, and prominent after being stuffed. For all standing soft stuffed toys, we will double check the fillings of the legs are solid and strong enough. When sitting plush stuffed animals our team will especially check the filling of the hips and waist.
The size, shape, and weight of plushes toys must be consistent with the plush prototype client approved, Any discrepancies with the PP sample are unacceptable. In addition, the plush animals that have burst holes after cotton filling, or fabrics have been withdrawn are all categorized as defective products.
Hand stitching and brushing
In this step we required the stitch length must to be no less than 10 stitches per inch, the knotted thread ends cannot be exposed, feeling the existence of gaps outside the seam by hand picking is totally NOT acceptable, and PP cotton should not seep out from the seam after the stitched. Meanwhile, after brushing, the direction of the fur, the plushies’ expression, all details must same as the sample client signed back.
Accessories
Check all the small parts like now-tie, buttons or some decorative parts must be stitched firmed enough and able to pass the 4lbs stretching test after stitching. Moreover, double-check the plastic needles for “the hangtags” must be totally exposed outside of the plushies instead of “inside”. This action for us means a lot to control the plushies’ production quality and safety.
Cleaning and needle detection
Start to inspect and clean all finished plush cuddle toys. Then confirm the metal detection machine can work in good condition before putting the goods on it, the related QC team will do the record and submit the files. Goods un-detect and being detected will be put in the different cartons and different spots to recognize.
Final packing
Our production team will check if all packing accessories are the same as the order indications before work, including opp bags with air holes and suffocation warning, the barcode checking, shipping mark, etc. After these steps, the goods were ready to accept the internal QC team sampling inspection.
Conclusions:
We’ve been producing and exporting customized plushes for 10 years. we are constantly improving our internal processes and services for every project. Plushtoysmfg always commits to providing our customers with safe, high-quality plush toys at a good value. Our prices might not the lowest, but we can assure you we’re the most suitable supplier for you.