Monday, December 22, 2008

Season's Greetings!

We want to wish you a magical holiday, sprinkled with good fortune and happiness! It has been a wonderful year, we are blessed to have such great friends and retailers.
The Chinese New Year of the cow/ox begins January 26 - if you want to read your 2009 fortune click here: http://www.chinesefortunecalendar.com/
Cheers! Mary, Justin, Jack (5) and Teddy (1)
Mooncakes founder & support staff :)

Saturday, December 6, 2008

Factory visit - the baby garment process!


We had the joy of visiting our factory in early November, it's located 2 hours north of Hong Kong in Shenzhen, China. I want to share the manufacturing process of a baby outfit, so many steps!

1. Make designs here in Florida, send samples back and forth (can take up to 6-12 months to get it right), samples are approved.

2. The patterns are created on a computer, the fabric is ordered - either dyed or screen printed (takes 30-60 days for this part). When fabric arrives it's checked with a flat roll machine, any problem parts are removed.

3. The fabric goes to the cutting room with hand cutting machines (see picture on near right), with patterns the fabric is cut for an outfit: the body, then legs, arms, etc... here the men do the cutting.

4. After the cutting room the fabric pieces get embroidered or appliqued one by one, then move to the sewing room and all the pieces are sewn together by hand. Care labels and woven labels are sewn on last. The women do most of the sewing: ages 25-50.

5. After sewing, garments are inspected by a few women to cut off extra strings, and checked again.

6. Then the garments move to the pressing room (they get wrinkled in the sewing stage), here the men do the pressing with irons.

7. After the garments are pressed they are inspected once again for a final quality control sign off - and folded so neatly, hangtags are attached, and put in clear polybags (see picture on top).

8. The garments are organized by style and size; and packed in cartons.

9. A driver takes the many cartons to the big Hong Kong port, where the cartons go to a freight forwarding warehouse and get placed in a container on a huge ship - and 30 days later arrive in Miami ready for our US customs broker to clear the shipment. It's truly an amazing process (and stressful at times getting all the puzzle pieces to match up).

We have the good fortune of a reliable factory and wonderful people to do business with!