Here at the ODM Group, we often schedule visits with the factories we are collaborated with. This not only ensures the quality standards are respected but also allows us to check that production is on schedule.
It is certainly essential for us to be involved as much as possible. From the first spark of an idea of a promotional product all the way down to its manufacturing and shipping to your chosen destination. Our promotional product services ensure the process is as smooth as possible.
Our ODM Group team members recently visited a factory that makes plush toys in Dongguan, Guangdong Province, China. During the trip, we had a chance to take a look at all the steps of production, in order to find out more about the process of manufacturing these items.
Plush toys make for a great gift with purchase or personalized promotional products. They are popular, customizable and also allow you to extend your brand remembrance beyond the shop floor! Consequently factories in China have plenty of experience making them.
Stage 1: Designing the Product
First of all, the initial stage of each project involves the design team drawing out the plush toy. From here they select from a wide range of fabrics and draw the template design onto the fabric. They cut this design out and use a sewing machine to stitch the material of the plush toy together. An intricate complex design that has different colors and felts involved takes, on average, 25 minutes to make each sample.
Making plush toys, you may select any fabric available like cotton, polyester, velvet, wool etc. But in modern toy production most fabrics are made of polyester in a great variety of fibre length, thickness and colours.
Whilst these toys are produced on mass, it was surprising to see the constant hand-attention that is required during the design and production process.
Stage 2: Producing the Cotton
Producing plush toys certainly demand a lot of cotton! Factories by yarn-like cotton then this is put through a machine to be turned into fluffy cotton.
Below is an image of the cotton: how it is bought vs. what it is turned into.
Check out this video! This machine turns cotton yarn like cotton into soft, fluffy cotton wool that is then suitable to stuff in plush toys.
Stage 3: Filling the Plush Toy
Each plush toy has a small hole left during sewing to form the entrance for stuffing. They are stuffed until they get to the desired level of softness or denseness. Often, this is used with cotton, polyester filling and plastic pellets – to give the toys a ‘beany’ feel. Therefore the plushyness of the toy can be made to a desired feel.
Stage 4: Metal Detector
Interestingly, every plush toy goes through this metal detector at the end of their production to ensure no needles are lost within the plush toy. Above all this is to ensure the safety of the toy once it has left the factory.
All of the products are sewn therefore it is vital to ensure there are no loose needles.
Stage 5: Quality Check
Every item is checked by hand to ensure it meets the high standards expected of a plush toy. This involves looking out for any loose threads and ensuring consistency with the product size, feel and design. Even more quality checks are done once the items reach our Zhuhai office to ensure products are up to impeccable standards.
Stage 6: Shipping!
This machine is used to load the boxed goods into a lorry or truck. This special device works as a crane to hoist the goods. Our products are, from here, shipped all over the world!
Why factory visits are important:
Wondering about how the workers get paid for their input?
Check out these common manufacturing problems and ways to overcome them. A really interesting read:
Thinking of producing plush toys for your own company?
We hope this blog gives you an insight into the manufacturing process of producing plush toys. If you are interested in this or any of our other products get in touch. Our specialist design team Mindsparkz will be happy to assist you with the design of any product. ODM will be delighted to manage the production process. Feel free to get in touch and let us assist you in coming up with some new and innovative ways to promote your brand!
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Finally, do you want to know more about building up a factory network? Look no further!