Elastic Inspection Procedure in Garment Manufacturing: A Complete Guide to Quality, Safety & Compliance

In modern garment production, elastics are more than just functional components — they are critical elements that affect garment fit, comfort, and longevity. Whether used in waistbands, cuffs, sportswear, or lingerie, elastics must meet high standards of stretch, recovery, shade, and safety to satisfy global buyers and ensure customer satisfaction.

This guide outlines a comprehensive Elastic Inspection Procedure followed in leading garment factories — combining physical, functional, and safety checks to achieve zero-defect quality.

---

🎯 Purpose of Elastic Inspection

The primary goal of elastic inspection is to ensure that every roll or piece of elastic received in the factory is:

• Defect-free

• Meets elasticity and recovery standards

• Color-matched with approved samples

• Safe, metal-free, and eco-compliant

A systematic inspection process helps prevent costly rejections, production delays, and quality complaints from buyers.

---

🧩 Scope of the Procedure

This procedure applies to all kinds of elastics used in apparel manufacturing, including:

• Woven or knitted elastics

• Jacquard and waistband elastics

• Braided or lingerie elastics

• Sportswear and functional elastics

Each type undergoes the same quality assurance process with specific focus based on buyer or product category.

---

👥 Roles & Responsibilities

A successful elastic inspection system involves coordination across multiple departments:

• Quality Auditors/Inspectors: Conduct all tests and record findings.

• Store Team: Ensure only passed elastics are issued for production.

• Merchandisers: Verify supplier documentation and communicate failures.

• Suppliers: Provide latex-free, eco, and metal-free certifications.

---

🧰 Equipment & Requirements

Before starting inspection, the following tools and references should be ready:

• Buyer-approved Elastic Standard Sample

• Light Box / Color Assessment Cabinet (calibrated annually)

• Elastic Stretch Test Equipment

• 4-Point Fabric Inspection Machine

• Washing Equipment for durability test

• Metal Detector (calibrated and sensitivity verified)

• Elastic Inspection Report (SGL-QA-FO-039)

---

🔍 Step-by-Step Elastic Inspection Process

1️⃣ Sampling

Select 10% of the total lot randomly for inspection. For new suppliers or critical programs, sample up to 15–20%.

---

2️⃣ Expiry & Identification Check

Ensure each roll is labeled with:

• Product code

• Lot number

• Expiry date

Reject any lot without clear identification or expired material.

---

3️⃣ Physical Defect Inspection – The 4-Point System

The 4-Point Fabric Inspection System is a globally recognized method for identifying physical defects in continuous materials like elastic rolls.

Defect Scoring Table:

Defect Length	Points
Up to 3 inches	1
3–6 inches	2
6–9 inches	3
9-36 inches	4

After scoring, calculate total points per 100 yards:

$$\text{Points per 100 yds} = \frac{\text{Total Points} \times 100}{\text{Yards Inspected}}$$

Acceptable Limits:

• Visible/Waistband Elastic: ≤ 20 points

• Internal/Hidden Elastic: ≤ 28 points

---

4️⃣ Elasticity & Recovery Test

Check how much the elastic can stretch and how well it returns to its original length.

Method:

• Stretch to 100–120% of original length.

• Release and measure recovery after 30 and 60 seconds.

• Compare results with approved samples.

Reference: ASTM D2731-21

---

5️⃣ Shrinkage & Wash Durability Test

Using the pillow method, sew elastics between two fabric pieces and wash them (at least 3 cycles).
After washing, measure shrinkage and test recovery again.

Tolerance: ≤ 3% unless buyer specifies otherwise.

If results exceed limits → pre-wash 100% of the lot before bulk use.

---

6️⃣ Color & Shade Matching

• Check shade against approved sample under TL83 (primary) and D65 (secondary) lights in a calibrated light box.

• Reject elastics showing shade mismatch or metamerism (color variation under different lights).

---

7️⃣ Latex-Free & Safety Verification

Buyers increasingly require latex-free materials due to allergy risks.

• Confirm supplier latex-free declaration or lab report.

• Check for unusual odor or chemical residue.

• Ensure compliance with OEKO-TEX®, ZDHC, and RSL standards.

---

8️⃣ Metal Detection — A Must for Modern Compliance

Every roll of elastic must pass through a calibrated metal detector to ensure it’s free from metallic contamination such as broken needles or staples.

Recommended Sensitivity: 1.2

If the detector alarms, segregate the roll immediately and recheck after cleaning or supplier replacement.

---

9️⃣ Defect Percentage Calculation

To determine lot quality:

\text{Defect %} = \frac{\text{Defective Rolls}}{\text{Inspected Rolls}} \times 100

Compare with AQL 1.5 or buyer-specific criteria.
If above AQL → hold lot, issue NCR, and request corrective action.

---

🔟 Decision & Record Keeping

Condition	Action
Passes all tests & metal detection	Approve for bulk
Minor issue within tolerance	Approve with remark
Major defect or contamination	Hold for recheck
Repeated failure	Reject and return to supplier

Maintain all records, including:

• Inspection reports

• Test data (stretch, recovery, shrinkage, color)

• Metal detection logs

• Supplier certificates (latex-free, OEKO-TEX)

• Mockup retention samples (minimum 6 months)

---

📋 Documentation & References

• SGL-QA-FO-039: Trims & Accessories Inspection Report

• ASTM D2731-21: Elastic properties of elastomeric yarns

• AAMA 4-Point System: For physical defect inspection

• OEKO-TEX®, GOTS, ZDHC: Environmental compliance guidelines

• Metal Detection Calibration Certificates

---

🌱 Why This Procedure Matters

Implementing a structured Elastic Inspection Procedure ensures:

• Consistent product performance

• Buyer and regulatory compliance

• Reduced rework and claim costs

• Safer garments, especially for children’s wear

• Sustainability and traceability in supply chains

---

💡 Final Thoughts

Elastic quality might seem like a small detail — but in the eyes of a global buyer, it defines the comfort, reliability, and integrity of the finished product.
By combining 4-point inspection, functional testing, and metal detection, factories can achieve world-class quality standards and build lasting trust with customers.