Auteur : Sophie Chen
Date: 29 Dec,2024
In the previous article, we learned that the minimum order quantity (MOQ) varies due to the different fabric widths in the manufacturing process.https://blog.docsunhomeandliving.com/how-fabric-sizes-affect-minimum-order-quantity/ In this article, we will delve deeper into how the production processes, such as knitting, weaving, dyeing, and shuttle weaving, impact the minimum order quantity.
In many industries, especially in textile production and customization, we often encounter the requirement of a Minimum Order Quantity (MOQ). This requirement often leads to questions from clients when placing an order: Why do some products require a minimum quantity to be ordered? Why does my supplier always say it’s impossible to produce 20 pieces in one color or 10 colors with 20 pieces each? To address this, I’ve written a series of articles titled ‘Why Customized Partnerships Have a Minimum Order Quantity: An Analysis of Multiple Influencing Factors’. This article explores how craftsmanship influences the Minimum Order Quantity (MOQ).
Knitting and Small Minimum Order Quantity (MOQ)
Production Process Characteristics:
The production process of knitted fabrics is relatively simple and typically involves using knitting machines to interlock yarns to form the fabric. Compared to woven fabrics, knitted fabrics offer higher elasticity and flexibility in production. Knitting usually requires fewer equipment adjustments and allows for easier small-batch production. Additionally, knitted fabrics, such as those used for sportswear, are often readily available in the market in stock, which further facilitates low MOQ for these types of products. For example, the MOQ for a single color is typically around 100-150 pieces.
Reasons for Small MOQ:
Production Flexibility: The knitting process does not rely on complex equipment adjustments, and the production cycle is relatively short. As a result, manufacturers can fulfill smaller order quantities within a shorter time frame.
Adaptability to Small-Batch Customization: Knitted fabric production can be easily adjusted to meet customer needs in terms of style, color, and fabric characteristics. This makes it ideal for small, diversified production demands, allowing for customized orders with relatively low MOQ.
Weaving and Medium Minimum Order Quantity (MOQ)
Production Process Characteristics:
The weaving process typically involves the interlacing of longitudinal warp yarns and horizontal weft yarns using a loom to form the fabric. Compared to knitting, the weaving process is more complex, requiring a longer production cycle and more equipment adjustments. Customization of woven fabrics is highly varied, and there are fewer ready-made fabrics available in the market. This leads to a medium MOQ for woven fabric products. Additionally, some woven fabrics are produced using hand-weaving techniques, which generally result in a bigger MOQ. Currently, hand-woven fabrics usually have an MOQ of over 200 pieces, while woven fabrics made using looms typically require an MOQ of 500 pieces or more.
Reasons for Medium MOQ:
Equipment and Setup Costs: The production of woven fabrics requires more adjustments and settings on the looms, and the production cycle is longer. As a result, manufacturers generally prefer to produce in larger quantities to recover the costs associated with equipment and production setup.
More Fixed Production Patterns: Woven fabric production involves fewer changes in style or fabric variations during a single production run. The process is typically more stable and requires larger batches to maintain consistency in production. Frequent changes in design or material would increase production costs and disrupt the efficiency of the process, making smaller runs less cost-effective
Yarn-Dyeing (Color Weaving) and Large Minimum Order Quantity (MOQ)
Production Process Characteristics:
The production process of yarn-dyed fabrics involves the use of differently colored warp and weft yarns that are interwoven during the textile process. This requires highly precise equipment and technical control. Since yarn-dyeing involves coloring the yarns before they are woven into fabric (as opposed to dyeing the fabric afterward), the process is more complex and expensive. Yarn-dyed fabrics are custom-made and rarely available as ready-made stock, so the MOQ is typically in the thousands.
Reasons for Large MOQ:
High Cost and Complex Process: The production of yarn-dyed fabrics requires precise control over the dyeing of the yarns, weaving density, and pattern design. This makes the process more intricate and time-consuming. To ensure consistent quality and minimize the cost per unit, manufacturers usually prefer large-volume orders that allow them to amortize the higher production costs over more units.
Higher Equipment Requirements: Yarn-dyed fabrics require specialized equipment and technical support. The adjustments and maintenance of production equipment are costly, contributing to the need for larger order quantities to achieve cost efficiency. The high precision required for color matching and pattern consistency adds to the overall production expense.
Shuttle Weaving and Flexible Minimum Order Quantity (MOQ)
Production Process Characteristics:
Shuttle weaving is one of the most traditional weaving methods, where a shuttle is used to pass the weft yarn through the warp yarns, interlacing them to form fabric. Shuttle-woven fabrics are typically known for their durability and sturdy texture, making them suitable for high-strength, wear-resistant fabrics such as suit fabrics, workwear, and bed linens. Fabrics like silk and wool are also widely used in shuttle weaving. Additionally, the market has a large stock of shuttle-woven fabrics available, which contributes to the flexibility of MOQs in shuttle weaving.
MOQ Characteristics:
Stock Fabrics: When using existing stock fabrics in common colors, such as in the case of pillowcases, the MOQ typically ranges from 50 to 100 pieces per color.
Custom-Dyed Fabrics: If custom dyeing is required, the MOQ generally rises to 200 pieces or more per color.
Independent Development: If the customer is unsatisfied with the available stock fabrics’ composition or weaving techniques and requires independent development, the MOQ can increase to over 5,000 pieces to justify the development costs and ensure a viable production process.
Although the shuttle weaving process is similar to traditional fabric production, the maintenance and adjustment of the equipment take a longer time, and the process itself requires time and cost for experimentation. Therefore, larger order quantities are needed to achieve higher production efficiency, lower costs, and ensure profitability.
Summary and Recommendations
If entrepreneurs or brands are in the early stages of their startup, it is advisable to use knitting processes to create products or choose ready-made shuttle-woven fabrics with dyeing or digital printing. These options allow for lower minimum order quantities (MOQ) and greater flexibility, which is more suitable for small-scale production.
As the entrepreneur or startup brand grows and reaches a certain scale, I recommend gradually experimenting with weaving processes and custom dyeing, as these offer greater design flexibility and opportunities for differentiation.
However, for yarn-dyeing (color weaving) and shuttle-woven fabric development and customization, this is a field that requires great caution. We do not recommend that entrepreneurs or startup brands attempt to mimic the techniques of luxury brands in these areas, as they require large MOQs and come with significant development time and costs. These time and costs are typically absorbed by the high margins of luxury goods or large brands. This is also why the craftsmanship of luxury brands and major companies acts as a barrier to entry for smaller players.
