Ordering too little fabric can stop production. Ordering too much ties up cash and leaves dead stock. The goal is to buy enough polyester fabric for the real production requirement with a controlled buffer.
Why This Matters
Fabric requirement is affected by size ratio, consumption, marker efficiency, roll defects, shade grouping and rejection. A flat percentage added to order quantity is often too crude.
Key Components
- Order quantity by size
- Approved fabric consumption
- Marker efficiency
- Cutting wastage
- Fabric inspection rejection
- Shade segregation allowance
- Sampling and replacement quantity
- Expected order changes
Practical Method
Calculate consumption by size and multiply by order quantity. Add approved allowances separately rather than hiding everything inside one large percentage. Review historical actual usage for similar styles before placing the fabric order.
Working Example
If a 5,000-piece order averages 0.19 kg per garment, theoretical requirement is 950 kg. Add only justified allowances for cutting, defects, sampling and replacement to reach the final booking quantity.
What Buyers and Factories Should Check
- Use final size ratio
- Confirm approved consumption
- Check stock already available
- Review shade-lot constraints
- Plan replacement quantity
- Track actual usage during cutting
Common Mistakes
- Using one standard wastage percentage for every style
- Ignoring size mix
- Booking before marker approval
- Buying excess because calculation is uncertain
- Ignoring shade grouping
Best Practices
- Use a fabric requirement sheet
- Separate base quantity and allowances
- Compare planned vs actual consumption
- Update future allowances using production data
Final Thoughts
Good fabric planning protects delivery dates and working capital at the same time. The best system uses measured consumption plus transparent allowances.
Need Help With Polyester Fabric Sourcing?
Send Walrus – Yes India Can your garment type, GSM, DIA / width, colour, quantity and end use. We can help shortlist suitable polyester fabric options for bulk production.
Call / WhatsApp:
+91 90472 77722
+91 90420 77722
Website: yesindiacan.in
