You’ve placed the order. The factory says production is done. Your freight forwarder is asking for a loading date. Everything feels on track — until the shipment arrives and half the garments have broken zippers, wrong measurements, or colour that doesn’t match your approved sample.
For garment buyers sourcing from Bangladesh, China, Vietnam, or Turkey, this scenario is far more common than it should be. The fix is straightforward: a Pre-Shipment Inspection (PSI) conducted by an independent third-party inspector before your goods leave the factory.
This guide explains exactly how PSI works for garment buyers, how AQL sampling is applied, what defect classifications mean in practice, and how to read your report to make a confident Pass or Fail decision.
What Is a Pre-Shipment Inspection?
A Pre-Shipment Inspection is an independent quality check conducted when at least 80% of your order is fully produced and packed, but before the container is loaded. A qualified inspector visits the factory, draws a random sample from your order using internationally recognised AQL (Acceptable Quality Level) standards, and checks those garments against your specifications.
The result is a detailed report — typically 20 to 40 pages — with photos of every finding, measurements, defect classification, and a clear Pass or Fail verdict, delivered within 24 hours.
Crucially, the inspector works for you — not the factory. Their job is to report what they find, not to protect the supplier relationship.
When Should You Order a Garment PSI?
Order a PSI on every order from every factory — at minimum. The exceptions where you might skip it (established factory, reorder of an identical product, very low-value shipment) carry real risk. A single defective container shipment from Bangladesh to the UK or USA can cost USD 15,000–50,000+ in returns, rework, or lost sales. A PSI costs USD 190–300.
If you’re ordering from a new factory, or if the product has complex specifications (multiple colours, embroidery, woven labels, special finishes), also consider adding a During Production Inspection (DUPRO) at 30–50% production to catch problems even earlier.
Understanding AQL Sampling for Garments
AQL stands for Acceptable Quality Level. It’s an international statistical sampling system (ISO 2859-1) that tells the inspector how many garments to randomly check — and how many defects are acceptable before the batch fails.
Here’s how it works in practice:
Step 1 — Determine Your Sample Size
The inspector uses your total order quantity and the AQL Inspection Level (usually General Inspection Level II for garments) to determine how many pieces to check.
Example: An order of 3,000 garments at General Level II = sample size of 125 pieces.
Step 2 — Apply AQL Thresholds by Defect Type
Most garment buyers use these standard AQL thresholds:
- Critical defects: AQL 0 — Zero tolerance. Any critical defect found = automatic Fail.
- Major defects: AQL 2.5 — Out of 125 pieces, if 8 or more have major defects = Fail.
- Minor defects: AQL 4.0 — Out of 125 pieces, if 13 or more have minor defects = Fail.
You can tighten or loosen these thresholds. High-end fashion brands often use AQL 1.5 for major defects. Value retailers may accept AQL 4.0. The thresholds should be agreed with your inspector before the inspection.
The 3 Defect Categories for Garments
Every defect found during inspection is classified into one of three categories. Understanding these categories helps you make informed decisions when you receive your report.
Critical Defects
Critical defects make a garment unsafe, illegal, or completely unusable. Examples include:
- Exposed sharp metal hardware that could injure a child
- Toxic or banned substances in fabric or dye (e.g. azo dyes above legal limits)
- Small parts on children’s garments posing choking risk
- Incorrect or missing legally required labelling (fibre content, care instructions, country of origin)
- Functional failure of a safety feature (e.g. a harness buckle that doesn’t lock)
One critical defect = automatic Fail. No exceptions.
Major Defects
Major defects make a garment likely to be rejected by the end customer or significantly reduce its value. Examples include:
- Broken, skipped, or uneven stitching visible on the outside
- Zipper not functioning smoothly or detaching from tape
- Measurement out of tolerance (e.g. chest width 2cm off spec)
- Colour shading or streaking visible to the eye
- Wrong fabric, lining, or trim versus approved sample
- Missing or wrong label (brand, size, wash care)
- Pilling, snags, or holes in the fabric
- Uneven hem or crooked seam visible in normal wear
Minor Defects
Minor defects are small imperfections that don’t affect function or significantly affect appearance. Examples include:
- Loose thread ends inside the garment (not visible when worn)
- Slight needle mark on fabric at seam start/end
- Minor chalk or soil mark on inside fabric that can be washed out
- Very slight measurement variation within tolerance
- Minimal uneven bartacking on a non-visible seam
Minor defects matter when they accumulate. 13+ minor defects in 125 pieces still triggers a Fail under standard AQL 4.0.
What Inspectors Check on Garments
A thorough garment PSI covers the following checkpoints. Before your inspection, provide the inspector with your tech pack, approved samples, and any specific concerns.
1. Workmanship
Stitching quality and density (stitches per inch), seam strength, bartacking on stress points, thread tension, lining attachment, and finishing quality throughout the garment.
2. Measurements
The inspector measures a sample of garments against your measurement spec sheet. Common failure points: chest width, body length, sleeve length, and inseam. Even a 1cm deviation across a size run can create fit problems at retail.
3. Fabric and Materials
Visual check of fabric hand feel, weight, and surface quality. Colour matching against approved lab dip or sealed sample using natural light. Checks for shading between rolls, pilling, snags, holes, or contamination.
4. Trims and Components
All zippers (function, pull, auto-lock), buttons (attachment, shank), snaps, buckles, rivets, elastic, lace, embroidery, print, and patches — checked against your approved sample and specification.
5. Labels and Marking
Brand label, size label, care label (wash symbols and fibre content per destination country requirements), country of origin label, and any regulatory compliance labelling (e.g. REACH, CPSC, Oeko-Tex reference).
6. Packaging
Folding method, polybag size and thickness, hang tags and barcodes (scanned where possible), carton labelling, units per carton, carton size and gross weight — all checked against your packing instructions.
7. Appearance On-Body
A sample of garments is tried on a dress form or a team member to check silhouette, drape, and overall appearance versus your approved sample.
Common Garment Failures Found at PSI
Based on inspections across Bangladesh, China, Vietnam, and Turkey, these are the most frequent reasons garment shipments Fail:
- Measurements out of tolerance — especially chest, body length, and sleeve
- Broken or skipped stitches — particularly at collar, cuff, and side seam junctions
- Colour shading between garments from different fabric rolls
- Wrong or missing wash care symbols for the destination market
- Zipper failure — especially on budget nylon coil zippers
- Fabric weight lighter than specification — factory substituting cheaper fabric
- Carton labelling errors — wrong style code, barcode, or destination
- Pilling or surface defects on brushed or knitted fabrics
How to Read Your PSI Report
A Global QC Gate inspection report contains:
- Cover page: Order details, inspector name, factory, date, and overall Pass/Fail verdict
- Quantity check: Units counted in cartons versus purchase order
- Measurement results: Table showing each measurement point, your spec, and actual result per size
- Workmanship summary: Defects found per category (Critical/Major/Minor), count, and AQL result
- Photo evidence: 50+ photos showing each defect type, labels, packaging, and overall appearance
- Defect detail table: Each defect listed with photo reference, classification, and count
- Final verdict: Pass, Fail, or Conditional Pass with written recommendations
If the report shows a Fail, you have three options: reject the shipment entirely, negotiate with the factory to rework defective units before shipping (and request a re-inspection), or accept under a price reduction. Your decision should depend on the severity and type of defects, your delivery timeline, and your customer’s expectations.
Book a Garment Pre-Shipment Inspection
Global QC Gate conducts garment PSI across Bangladesh, China, India, Vietnam, Turkey, Indonesia, and 14 other countries. Our inspectors are local, qualified professionals who specialise in apparel and textile inspection.
- Pricing from USD 190 per man-day
- Report delivered within 24 hours with 50+ photos
- AQL sampling per ISO 2859-1 — thresholds customisable to your specs
- Blockchain-secured, tamper-proof reports
Email info@globalqcgate.com or WhatsApp +65 8077 2167 to request a quote. Include your factory address, product type, quantity, and preferred inspection date — we confirm within a few hours.