A lot of hard work and dedication is put in while making a piece of lingerie. In the olden days, lingerie manufacturing was a solo or homemade affair, however, as its demand has risen over centuries, the process has moved to mass production and thus factories have emerged.
From simple corset and handmade underwear of yesteryears to more sophisticated materials and styles of today, lingerie manufacturing has its own legendary history. The latest manufacturing involves the usage of a wider range of materials like silk, rayon, cotton, Spandex/elastane, polyester and lace.
The making of lingerie needs raw materials which can be cotton, polyester or the mix. Spandex is a tree sap which needs processing at the premises prior to its usage. Other materials include metal hooks and eyes, straps, padding, cups and adhesives.
The manufacturing of new lingerie requires knowledge on the market demand, the right cuts plus size and production costs in order to be able to determine a market price. New product must also pass through the quality checks and specifications before they can be launched.
A prototype drawing is made for the market niche and computer programs are used to design sample pieces. In order to deliver what is of comfort to the customer, multiple prototypes are drawn and experimented on and finally the most suitable one is selected for quality check and fit. The next step is to manufacture it in some quantity for the designers and marketers to evaluate them before putting up for the final sale.
The process of manufacturing involves several steps with some employing the traditional bandsaw-like shearing devices while others use computer controlled laser to cut out the components which then are stacked and sent for sewing. The process of sewing can either be on or off the premises with in-succession sewing being more common.
Closure and labelling follows and this is usually done by machine with the labels being either on the side or the back. Where applicable, addition of hooks and eyes or buckles is stitched in and heat processed or ironed.
When the product is ready for packaging, it is sorted out by style, compiled in boxes and read by a laser as fully packed and forwarded to the holding area for transportation to the wholesaler.
Quality control takes into account the customer’s activities, product cleaning, durability of raw material used, colour fastness, shrink-resistance and stretch factor.
Finally the by product which is largely fabric matter is either recycled or disposed.