ODMasia is currently producing promotional knitted scarves in China for our clients and we arranged a factory visit/audit together with the customer earlier in the week. Keeping transparent relationships between our clients and factories are important to our team. Find out about the process of manufacturing custom embroidered scarves as we walk you through our recent scarf maker factory visit.

Promotional Scarf Production - Mountain of Scarfs

Promotional Scarf Production – Mountain of Scarfs

Scarves are great promotional products for sports teams, music festivals, or outdoor corporate events. They can be fully customized and offer a large area for branding. Not to mention they are practical promotional products able to keep your customers warm during winter months and outdoor events or while enjoying a football game on a cold weekend. Take it from us! Customers always appreciate and keep a practical gift.

The Promotional Scarf Production process combines both automated machine work and manual labour.

Promotional Scarf Production can be broken down into six different steps

Production stages span from creating the design, to manufacturing and packaging. Here is what our customer learned from his visit.

Step One

Firstly is creating the design of the scarf, selecting the patterns, the logos and wording our customer’s want. Each side of the scarf can have different designs but will need to use the same colours. Then comes the question, how will the knitting machine know what pattern to create? The design of the scarf is created on a computer and is saved in a certain file type which is then converted into a knitting program that the knitting machine will translate into your product.

Step Two

Next step is the choose the quality and type of textile to use. Once the textile is chosen, whether it be acryclic, cotton or satin, the fabric is brought to be dyed in order to match the colour that your client requested. This is a very important step and crucial to make sure that all pantone colors are according to the client’s demand.

 

Promotional Scarf Production - Scarf Production Automated Machines

Promotional Scarf Production – Scarf Production Automated Machines

 

Promotional Scarf Production - Scarf being Knitted in Automated Machine

Promotional Scarf Production – Scarf being Knitted in Automated Machine

 

Step Three

Thirdly comes the knitting process. Once all the fabric has been dyed correctly, it is brought to the knitting machines. The machine begins running the fabric through the machine (see picture on the left of machine with scarf being produced). The knitting program is loaded on to the electronic knitting machine, which stores the data of the design. These knitting machines are controlled electronically and one employee can supervise several machines at the same time in order to make sure there are no problems or glitches during production.

For knitted football scarves the machine can handle a total of five colours at the same time on an automated kitting machine.

The machine will keep knitting scarves repeatedly until there is no more thread. Manual labour comes into work at this moment, in order to reload fabric into the machine and also to cut all of the knitted scarves individually. The machine does not separate each scarf during the knitting process, once it finishes one scarf’s design it immediately begins a new one which is still attached to the previous one.

Depending on the stitch density, your scarf requires different machines for knitting. The knitting machines vary between 8 to 16 knitting needles per inch (many more needles per inch are possible), this is referred to as a 8 to 16 gauge machines. The higher the gauge the higher number of stitches are knitted per inch. Once the scarves are complete in knitting they are separated by cutting them loose individually before they are moved to the next process.

Step Four

Fourth part of the Promotional Scarf Production process is the ironing process. In order for the scarves to be nice and flat they are ironed on a steam board. Since the scarves are not closed at both ends, a board is slipped inside the scarf. Each scarf is then ironed thoroughly.

Promotional Scarf Production - Scarf Ironing Process

Promotional Scarf Production – Scarf Ironing Process

Step Five

Step five of the promotional scarf production process is the sewing of the tassels. The tassels are created with a different knitting machine (see pictures below). The tassels can be made in any colour even if it is a different then the ones on the scarf. Since they are manufactured independently there are no colour issues. Factory workers will then sow the tassels on each end of the scarf in order to complete the manufacturing process. A standard size for tassels is between 4cm and 6cm long. After the tassel is sewn on the scarf production process is complete.

Production and Sewing of Tassels

Step Six

Next and final step is the packaging. Before shipping the goods to your client you need to package each scarf individually in the packaging required by your client and to then prepare the cartons for shipping.   How about putting a paper insert if giving these away as an on-pack or cardboard header on the polybag for retailers.

Scarf Manufacturing Process

When placing orders for scarves please prepare ample time in order to make several production samples before placing the order. Don’t forget to schedule quality control inspection throughout the production of the goods in order to guarantee the quality of the scarves.

Contact ODMasia for assistance on the manufacturing, customization, and design for your scarf order. Find out more about our other factory visit experiences on production processes that product your personalised promotional items.

Interested in knowing about some other production processes? Check out the links below

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Why branded scarves are a good promotional product?

A scarf is a piece of fabric to wear around the neck to protect yourself from wind, warm weather or cold weather. They can be made from different materials such as linen, cotton or wool. Scarves are great promotional products for sports teams, music festivals, or outdoor corporate events. They can be fully customized and offer a large area for branding. Also they are very useful as they will keep your customers warm during winter months and outdoor events or while enjoying a football game on a cold weekend.

What’s the production process of scarves?

This process combines both automated machine work and manual labour.Step One is creating the design of the scarf, selecting the patterns, the logos and wording. Step Two is to choose the quality and type of textile to use. Step Three is the knitting process. Step Four is the ironing process. Step Five of the scarf production process is the sewing of the tassels. Finally the last step is the packaging.