Why Actual Production May Exceed the Ordered Quantity in Custom Clothing — And How We Handle It

In custom apparel production, it is not uncommon for the final output quantity to be slightly higher than the customer’s original order. For those new to garment manufacturing, this may seem confusing, so here’s a clear explanation of why this happens and how we manage it professionally.

1. Fabric Rolls Are Never Exactly the Same

Fabric suppliers sell fabrics by the roll. Every roll has a natural variation in weight and length:

• Some rolls are slightly longer

• Some are slightly shorter

• The variation usually falls within ±2kg

To ensure the order can be completed smoothly, fabric suppliers often allocate a little more fabric than requested. This extra fabric may eventually translate into extra finished garments.

2. Fabric Inspection and Pre-Shrink Treatment

Once the fabric arrives at our factory, it goes through several quality control steps:

• Color consistency check

• Density and construction check

• Defect inspection

• Pre-shrinking and resting for 24 hours

These steps are essential to guarantee stable sizing and quality but may also affect the total usable fabric.

3. Cutting Requires Spare Pieces to Cover Loss

During the cutting stage, factories must prepare spare pieces. These are critical for handling potential issues during:

• Printing

• Embroidery

• Sewing

• Repairing defects

If production runs smoothly with minimal loss, those spare pieces become extra finished garments.

4. Industry Standard: ±5% Production Tolerance

Many apparel factories worldwide include a standard clause in quotations:

“Final quantity may vary by ±5% due to normal production conditions.”

This tolerance exists because of natural material variations and the need for production backup. Customers who accept this allow the production process to run efficiently.

If a customer does not accept extra quantities, the surplus becomes leftover stock—and the factory must absorb the cost.

5. How We Handle Excess Production

Depending on customer preferences and purchase terms, we offer three solutions:

A. Accept ±5% tolerance and settle based on actual quantity

This is the industry’s most efficient and cost-effective option.

B. Customer wants exact quantity — surplus becomes factory inventory

The extra units will be stored, repurposed, or cleared by us.

C. Strictly controlled production upon request

We can produce the exact number required, but it involves higher risk, longer lead time, and possible additional fees.

Conclusion

Extra production in custom clothing isn’t a mistake—it’s a natural outcome of professional manufacturing. Clear communication and aligned expectations ensure a smooth collaboration and a reliable garment supply chain.

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