How is the bag made?

A comprehensive guide to making custom packages.

Starting your first bag project can feel like a daunting task, an exciting adventure, or something complicated that can leave you unsure where to start, which may be why you are here! Let us help you with this simple guide that will outline each stage of the bag manufacturing process that leads to the delivery of your bag.

Each stage cannot be completed until the previous stage is complete. It's a bit like a board game, your bag is the finish line! Here's how to make a bag.

Youcco is an experienced custom bag manufacturer in China, our team is a group of people who have been making handbags for many years. Chances are that one of us has already made the bag style you are interested in and applied our knowledge to your project. If we didn't come up with the concept you showed us, no problem! Let's try it, we'll love it.

1. Sketch

Rough edges or refined by designers

Every bag project starts with a sketch or mood board containing bag inspiration and preferences. To make bags, maybe you have a bag you want to copy and make your own? This started as a sketch at some point.

You can send us a basic drawing of the package with notes on what you are looking for and if required we can formalize it for you with a design visual with suggestions and alternatives.

Other considerations at this stage include defining the purpose of the bag, what is it for? Who will use it? This is the basis of an idea that helps determine the best fabric for the bag or the best way to fasten the bag closed.

2. Selection of components and fabrics

Consider Bag Hardware and Closure

Figure out what the bag looks like, how it fits, how it closes, how long the shoulder straps are, and then consider the type of fabric the bag is made of? What kind of strap will it have? PU webbing or cotton webbing? Will there be one or two straps, are they long or short, or both? ·

 The choice of fabric will depend on the purpose of the bag and your budget. You might opt for fair trade organic cotton for your eco bag, and you can choose from a range of weights from 4 ounces to 24 ounces, but your budget may only be for mid-range weights. The thicker and thicker the fabric, the more expensive it is. ·

Hardware is also considered at this stage. Are there buckles on the shoulder straps to close the bag? Branded metal poppers or Pantone matching poppers to close the pockets?

When these elements have all been initially selected, we can then quote your project based on the fabric required for the bag and the number of units you are ordering and details.

3. Papercraft

Bag blueprint created

So, you've decided what your bag should look like, how big it should be, and what material it should be made of. Your project offer will be approved and you have paid a deposit to activate your interest. We'll then make a paper model of the bag, determine where the folds should be, measure the panels, and meet the seam allowances. Zipper and button positions will be assigned and a more accurate representation of how the bag will look in real life is created on paper. It's a bag pattern or blueprint for what's coming next.

4. Manual sampling

Handmade Disposable Samples

After the first stage asking you what you want the bag for, what it should contain, how much weight it should hold and what size it should be, we will collect enough information from you to quote the bag and make it sampling.

Before proceeding to manufacture thousands of bags, we made a physical sample of one bag. It is handcrafted by our professional sample maker. She will order and cut enough fabric for two samples of your bag, as well as other accessories needed to make a pre-production sample of your bag.

When we have made the bag, we will send it to you by express.

Samples let you see the bag in the flesh. When you receive it, you can show it to your customers to get their feedback. It's important that you use it to see if what you want fits, put your phone in a phone pocket, hang it over your shoulder, see if they're long enough to sit on your shoulder (wear your coat, you wore a coat when trying on the bag because you'll probably be using it outside the house), maybe the shoulder straps need adjustment, and you didn't think about it before).

It is important to note that samples are made by hand and not on a production line or machine, which results in greater quantity consistency. It's also important to note that the structures or hardware used for the examples will be one-offs. It will be the same fabric type, for example it might be 7oz natural cotton. Will order and cut from 7 oz cotton spools, but enough for samples only. The fabric in the full production will be from a different batch and will be slightly different, or the hardware may be slightly different as it is bought in bulk for the full production and the sample is made from a one-off sample purchased at the stage . Most fabrics come from natural sources and even synthetic fabrics are produced in batches, so pre-production samples may vary slightly from full production samples.

Dye Swatches

In some cases the fabrics are Pantone matched. We will sample the bag in the colors in stock and send you a swatch dyed to a Pantone reference color. You will choose from your favorite color swatches the color that you think is closest to your Pantone reference. this is your choice.

Dyeing fabric may take 6-8 weeks. If you haven't had this long and need to dye the bag ASAP, we can overprint the fabric and color match so the outside of the bag will be the desired color and the inside of the bag will be white.

5. Design Modifications

Correction after sample evaluation

Sometimes at this stage, small adjustments are made to get the final bag right. Pockets on tote bags may be made larger or smaller, the gusset depth may be increased on shopping bags, or interior compartments may be added to better organize items. In rare cases, if the bag is wrong the first time, we will sample it again. For example, if we make a mistake, then we will sample again for free. If you want to make major changes to the function of the bag, then we may charge you again for samples.

6. The fabric is calculated according to the complete order and purchased according to the quantity

Sourcing Fabrics After Approving Samples

Prepare samples using paper models as blueprints. The fabric is calculated accurately, and other details are also refined. If the bag has a zipper, the length of the zipper is defined and purchased by quantity. If the zipper is Pantone matching then it will be produced at this stage. If the bag has embossed poppers, then they will begin their own production process ready to be assembled in the final bag construction. Woven labels, enamel badges or personalized bag zipper pulls will also be manufactured at this stage once samples are approved by you. The fabric being dyed is now dyed. Fabric is purchased and sent to a dye house where it is dyed to your approved color swatch. It is dried, prepped, then rolled up and sent back to the factory, ready to be cut in the next stage.

7. Cut out the fabric pattern

Create a pattern for each panel

When we receive fabric for bulk orders, pattern templates are created for the cutting machines, the fabric is cut and monitored by team members. This guarantees accuracy and consistency across all bags, from our minimum quantities of 250 pieces to larger quantities of over 10,000 pieces.

The bag may have many panels, so each panel will be cut to size with a small margin for each panel to be sewn together. The A4 tote bag will have two panels, a front panel and a back panel. Larger shopping bags will have the same front and back panels as tote bags, but will also require precisely cut gussets and side panels with the correct edge dimensions to allow for seams during construction.

8. Printing and decoration on individual panels

The bag panel being printed is sent to the decorator

Now the panels are cut to size and they are sent to a printer or decorator.

Associated decorators accept artwork interpreted on panels as EPS files with reference visuals including Pantone color references. Panels are finished to specification and sent back for build.

9. Production line planning

Factory schedule including your package items

In addition to the decoration of the bag panels and the procurement of bag accessories, there will be production line scheduling. The number of units in the order, the steps involved in making the bag, how long it will take to print or dye, and the delivery deadline will be taken into account. Returning from the desired shipping address, we will determine when the order needs to be packed, a quality control review, and then return to stitching the bag together.

The number of sewing stations for each bag, which parts will be stitched together and how many people will stitch each bag will be determined. When the job goes into production, who will sew the badge and where will the zipper be sewn. While working on your job, there will be other bag items being stitched together and at various stages of the process, so our production managers will take all of this into consideration when taking your job into production.

10. Individual Component Assembly

Fabric panels, zippers, pull tabs and handles are ready

All elements of bag accessories ordered so far have arrived. The fabric is returned from the dye house, the printer has returned all printed panels, the embroidery is complete, and the hardware has arrived and inspected against the purchase order. All components are assigned to your bag item and stored in a holding area ready for distribution to the associated assembly station on the factory floor.

11. Complete construction

All bag elements are pulled together

Bringing all the elements of the pack together was a team effort. From cutting and trimming the panels to sewing them together. It is done at the assembly station by a team of experienced people who have done it all before. There is no bag they didn't make. Everyone has a blueprint for the bag and a template to follow. Each element they are responsible for has a best practice example to follow and will ensure that the part they are working on is exactly like that example.

12. First stage quality inspection and loose wire cutting

Attention to finer details

The quality control manager will check the first batch of bags off the production line to initially check whether the production process is normal. Then assembly begins. Loose threads are cut short in the process, one of the quality team monitors progress as the order is assembled, there will be a checklist to complete, including print orientation, hardware in place, zippers sewn in the correct orientation, handle lengths exact, reinforced Handle stitching, lining included, pockets on the correct perimeter and on the correct panels, and more.

13. Quality control

Final inspection before packing and shipping

Now that all the bags are constructed, final quality control checks will begin. The bag is complete and should include all elements in the specification. The Quality Control Manager and her team will check a portion of the order against the checklist. Bags will be randomly selected from the completed order and inspected to ensure the bags are to the specifications described, but also to ensure they are perfect. Loose threads and imperfect prints will not be tolerated.

We employ an internationally renowned external audit team to audit over 5000 ordered assembled bags during production and prior to packaging. You can enter what you wish to check during the review.

14. Ironing

Bags are steamed or heat pressed to remove creases

Now that the order is complete and has passed quality control, the bag is ironed and folded for packaging. Bags are hung and steamed flat if required, or folded to order specifications. You may have requested that the bag include a hang tag during production, this may be added at this stage as the bag is ready to be packaged so that the hang tag lays flat and is protected when folded. You may have specified that the bags remain open if they have a closing mechanism to make filling the contents easier when you receive them, which will be done at this stage.

15. Packaging

Create a packing slip when loading cartons

As the bags go through the ironing and prep stages, they are packed to order specifications. We pack orders in protective compostable packaging before going into pre-sized cardboard shipping cartons. Depending on the size of your bag, it will depend on how much you can fit in the compostable protective bag. The packing slip that comes with your order will outline how many units are in a carton, and it will sound like this: 60 per carton / 10 cartons (600 total). There are 15 units per compostable bag in the 60 carton. The protective bag protects your order from moisture during transit or any unpleasant odors along the way.

We used to use plastic before we knew better. Now you'll find your order nicely wrapped in a biodegradable bag that you can use in your food compost bin and it will slowly break down without leaving a trace.

15. Transportation

Baggage order is in transit by sea or air

We price shipping on orders over 500 pieces by ocean. It is economical and environmentally friendly for you. You can expect 5-6 weeks to see delivery, and shipping by sea has far less environmental impact than by air, which is faster. We export sea containers from India every 2 weeks, so you can rest assured that your order will be dispatched as soon as it is ready to ship. Once it arrives in the UK it will be unpacked and inspected before being sent to our warehouse where we will send it via domestic courier to your nominated delivery address.

If you have a larger order and would like a case or two to be packed before the entire order arrives then we can arrange that. You can talk to your project manager about this.

Some customers order a large number of bags from us but don't want to order them all at once. We can store at our warehouse in Somerset, UK and send to you on demand. We charge a small storage fee for this and shipping is charged at cost.

Another thing you may have discussed with your project manager is our pick and pack service. You may have ordered luggage and other items from us that need to be packed with luggage before it is sent to your final delivery address. We can pick and pack all the elements for you and ensure your recipients receive exactly what you want them to receive.

So there you have it. Guidelines for making bags in quantities ranging from 250+ to tens of thousands of bags. All bag items are treated the same, whether you order a small quantity or a large quantity, you will receive the same attention and energy from start to finish. what are you waiting for? Email your sketches or send us your bag criteria list and we'll be happy to make the bag for you.