Starting your first bag project can feel like a huge task, an exciting adventure or
complicated and could leave you unsure on where to start, which is probably why
you are here! Let us help you with this simple guide that will outline each stage of the bag manufacturing process that leads to delivery of your bag.
Each stage cannot be finished until the previous one is complete. It’s a bit like a board game and your bag is the finish line! Here's how to make a bag.
Our experienced team in Somerset, UK are a great bunch of people who have been making bags for many years. Chances are that one of us will have made the style of bag you are interested in making and will apply our knowledge to your project. If we’ve not made a concept you present to us, then no problem! Let’s try it and we’ll enjoy it.
1. Sketch
Rough around the edges or refined by a designer
Every bag project starts with a sketch or mood board that includes bag inspiration and preferences. To make a bag you may have a bag you want to replicate and make your own?
This started off as a sketch at some point.
You can send us a rudimentary drawing of a bag that is annotated to explain what it is you are looking for and we can formalise that for you with a design visual that incorporates suggestions and alternatives if required.
Other considerations at this stage include defining what the bag is for, what will its purpose be? Who will use it? This is the foundation of an idea that helps determine the best fabric for the bag or the best fastening to close the bag.
·Fabric choice will be determined by purpose of the bag and your budget. You might
choose Fairtrade organic cotton for a planet-friendly bag and you can choose
from a range of weights starting at 4oz and going up to 24oz but your budget
might only lend itself to a mid-range weight. The heavier and thicker the
fabric, the more expensive it is.
·Hardware
is also considered at this stage. Are there buckles on straps to close the bag?
Branded metal poppers or Pantone matched poppers to close a pocket?
When
these elements are all initially selected then we can quote your project based
on fabric required for the bag and number of units that you want to order
plus the detailing.
3. Paper mould
Bag blueprint is created
So,
you’ve worked out what your bag should look like, how big it should be and what
it will be constructed of. Your project quote will be approved, and you’ve paid
a deposit to launch your intention. We will then make a paper mould of the bag
and work out where it should be folded, panels are measured, and seam
allowances catered for. Positioning for zips and buttons will be allocated and a
more accurate image of what your bag will look like in real life is created in
paper. This is the bag pattern or blueprint for what happens next.
Sometimes at this stage, small adjustments are made to get the final bag right. Pockets may be made bigger or smaller on a tote bag, the depth of a gusset on a shopper bag may be increased in size or internal compartments may be added to organise the contents better. In rare cases, we sample again if the bag isn’t right first time. If we’ve got it wrong for example, then we’ll sample again for free. If you want to make big
changes to the features of the bag, then we may charge you to sample again.
6. Fabric calculated for full order and sourced in quantity
On approval of the sample the fabric is sourced
The
sample is prepared using the paper mould as a blueprint. Fabric is accurately
calculated, and other details are also refined. If the bag has a zip, then the
length of zip is defined and sourced in quantity. If the zip is Pantone-matched,
then it will be manufactured at this stage. If the bag has embossed poppers, then they
will start their own production process ready to be assembled in the final bag
construction. Woven labels, enamel badges or personalised zip pulls for bags
will be also be manufactured at this stage, once the sample has been approved
by you.
Fabric
that is being dyed will begin now. The fabric is purchased and sent to the
dying mill and is dyed to the colour swatch approved by you. It is dried, prepared
and then rolled up and sent back to us in the factory ready to be cut out in
the next stage.
7. Fabric pattern cut out
Pattern for every panel is created
When
we receive the fabric that has been ordered in bulk, the pattern template is
created for the cutting machine and the fabric is cut out and monitored by a
member of the team. This guarantees accuracy and consistency across all bags
from our minimum quantity of 250 to larger quantities of 10,000+.
The
bag may have many panels, so each panel will be cut out to size, each with a
small margin to allow for sewing together. An A4 tote bag will have two panels, a front and back
panel. A larger shopper bag will have the same front and back panels seen in a
tote bag, but also a gusset and side panels that also need to be cut accurately,
with their correctly sized margin to allow for seams during construction.
8. Print and decoration on individual panels
Bag panels being printed are sent to the decorator
Now
the panels are cut to size, they are sent to the to printer or decorator. The
relevant decorator accepts the artwork to be interpreted onto the panels as an
EPS file, as well a visual for reference that includes Pantone colour references.
The
panels are decorated in accordance with the specification and then sent back to
be constructed.
9. Production line planning
Factory schedule includes your bag project
Alongside
the decoration of the bag panels and sourcing of accessories for the bag,
production line scheduling will be taking place. The number of units in the
order, the steps involved in constructing the bag, how long the print or dying
will take plus the deadline for delivery will be considered. Working back from
the desired delivery address, we will work out when the order will need to be
packed, the quality control audit, right back to the bag being sewn together.
The
number of sewing stations per bag will be determined, which sections will be
sewn together and by how many people. Who will be sewing the badges on and
where the zips are sewn in will all be considered when the job is slotted into production.
There will be other bag projects being sewn together and at different stages of
the process while your job is being processed so our production manager will be
considering all of this while placing your job into production.
10. Individual component assembly
Fabric panels, zips, poppers and handles are prepared
By
now, all elements for accessories for the bag that have been ordered, have
arrived. Fabric is back from the dying mill, the printer has returned all
printed panels, the embroidery is complete, and the hardware has arrived and
been checked against the purchase order. All components are allocated to your
bag project and stored in a holding area ready to be distributed to the
relevant assembly stations on the factory floor.
11. Complete construction
All bag elements are pulled together
Getting
all the elements of the bag together is a team effort. From the cutting of the
panels and decoration to sewing it all together. It is done at assembly stations
and by a team of experienced people who have done it all before. There isn’t a
bag they haven’t made. Each person has a blueprint for the bag and a template
to follow. Each of the elements they have been tasked with has a best practise
example to adhere to and will ensure the section they are working on will be
precisely the same as that example.
12. First stage quality check and loose threads cut
Attention to finer detail is refined
The
Quality Control Manager will be checking the first bags made off the production
line for the initial check that the production process is working. Then
assembly commences. Loose threads are cut short during the process and one of
the quality team monitors progress as the order is assembled, there will be a
checklist to work through that includes print direction, hardware in place,
zips sewn in the facing the correct direction, handle length precision,
reinforced handle stitching, linings included, pockets the right way around and
on the correct panel and so on.
13. Quality control
Final checks prior to packing and shipping
Now
all of the bags are constructed, the final quality control check will commence.
The bags are complete and should include all elements within the specification.
The Quality Control Manager and her team will inspect a proportion of the order
against the check list. Random bags will be taken from the finished order and
checked to ensure the bags are as per the described specification but also that
they are finished to perfection. Loose threads and imperfect print will not be
tolerated.
We
use an internationally acclaimed external audit team to review assembled bags
during production and prior to packing on orders of over 5000 units. You can
have input on what you would like to be checked during an audit.
14. Ironing
Bags are steamed or heat pressed to remove creases
Now
the order is complete and has passed quality control, the bags are ironed and
folded for packing. Bags will be hung and steamed flat if required or folded in
accordance with the order specification. You may have asked that the bags
include a swing tag to be included during production and this may be added at
this stage as the bag is prepared for packing so that the swing tag lies flat
and protected during folding. You may have specified that the bags are left
open if they have a closing mechanism to make it easier to stuff with contents
when you receive them, this will be actioned at this stage.
15. Packing
Packing lists are created when cartons are loaded
As
the bags pass through ironing and preparation stage, they are packed in
accordance with the order specification. We pack our orders in protective compostable
packing prior to going into the cardboard shipping carton which are
predetermined sizes. Depending on the size of your bag, will depend on how many
can fit in the compostable protective bags. The packing list provided with the
order will outline how many units are in a carton and will sound something like
this: 60 units per carton / 10 cartons (600 units in total). There would be 15
units per compostable bag in a carton of 60. The protective bag protects your
order from getting damp in transit or picking up any nasty smells along the
way.
We
used to use plastic before we knew better. Now you will find your order wrapped
nicely in a biodegradable bag that you can use in your food compost caddy and
it will gently decompose and leave no trace.
15. Shipping
Bag order is in transit by sea or air
·We
price shipping for orders of over 500 units to be shipped by sea. It’s cost
efficient for you but also kinder to the environment. You can expect to see
delivery take 5-6 weeks and the impact of sending it by sea is far less
intrusive to the environment than sending it by air, which is quicker. We
export shipping containers from India every 2 weeks and you can be sure that
your order will shipped as soon as it becomes ready for dispatch. Once it
arrives in the UK, then it is unpacked and checked then sent to our warehouse
where we dispatch it by domestic courier to your allocated delivery address.
·If
you have a larger order and would like a carton or two of bags prior to the whole
order arriving, then we can arrange this. You can talk to your project manager
about this.
·Some
clients order large quantities of bags from us but don’t want the whole order
at once. We can store in our warehouse in Somerset, UK and dispatch to you as
required. We charge a small storage fee for doing this and shipping is charged
at cost.
Something
else you might have discussed with your project manager is our picking and
packing service. You may have ordered bags from us plus other merchandise that
needs to be packed with the bags prior to dispatching to your end delivery
address. We can pick and pack all elements for you and ensure your recipients
are receiving the elements you want them to.
So, there
you have it. A guide to making a bag in quantities from 250+ to tens of
thousands of bags. All bag projects are treated the same, whether you are
ordering a smaller quantity or larger, quantity, you will receive the same attention
and energy from start to finish. What are you waiting for? Email over your
sketch or send us a list of your bag criteria and we’ll be delighted to make
your bag.