EFL Factory
Manufacturing Excellence

End-to-End Manufacturing
Capabilities

From raw fibre to finished garment — EFL controls every stage of production with precision engineering, cutting-edge technology, and a skilled workforce of 3,100+.

3,100+
Skilled Workers
30M+
Pieces / Year
25+
Export Markets
45+
Sewing Line
Our Workflow

From Concept to Delivery

A rigorous 8-stage manufacturing pipeline ensures every garment leaving our facility meets the highest international standards.

Stage 01

Design & Merchandising

Our in-house design and merchandising team translates buyer briefs into detailed tech-packs, ensuring every specification — fabric, trim, construction — is captured before a single stitch is made.

  • Buyer brief interpretation & tech-pack development
  • CAD pattern drafting & 3D virtual sampling
  • BOM (Bill of Materials) preparation
  • Costing & lead-time planning
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02
Stage 02

Fabric Sourcing & Inspection

We partner with certified yarn and fabric mills across Bangladesh, India, and beyond. All incoming materials undergo AQL testing and lab analysis before entering production.

  • Certified mill partnerships (GOTS, OEKO-TEX)
  • Incoming fabric AQL 2.5 inspection
  • Shade, shrinkage & pilling tests
  • Trim & accessory verification
Stage 03

Sampling & Proto Approval

Multiple sample rounds — proto, fit, salesman, and pre-production — are conducted and sent to buyers for approval, ensuring zero surprises during bulk production.

  • Proto → Fit → Size-set → PP sample rounds
  • Buyer comment incorporation & re-submission
  • Sealed sample retention for production reference
  • Average sample lead time: 7–10 working days
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04
Stage 04

Cutting & Spreading

Computer-aided spreading and precision cutting ensures minimal fabric wastage and consistent component sizes. Our CAD-driven marker planning achieves up to 88% fabric efficiency.

  • Auto-spreading machines (Eastman, Gerber)
  • CAD marker planning for fabric efficiency
  • Fusing, numbering & bundling by size/colour
  • Cut panel 100% count verification
Stage 05

Sewing & Assembly

Our sewing floors operate on modular production lines equipped with specialised machines for every stitch type. Inline quality checks occur at every operation, catching defects before they compound.

  • 1,200+ sewing machines (JUKI, Brother, Pegasus)
  • Modular line balancing for productivity
  • Inline QC at every operation point
  • Flatlock, overlock, cover-stitch & bartack specialisation
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06
Stage 06

Washing, Finishing & Embellishment

From enzyme washes to pigment dyeing, our in-house laundry and finishing facility handles a full spectrum of treatments. Embroidery and print are executed by our dedicated value-add unit.

  • In-house washing: enzyme, stone, garment dye
  • Screen print, sublimation & digital print
  • Embroidery: up to 24-head machines
  • Heat transfer, rhinestone & appliqué work
Stage 07

Quality Control & Inspection

A dedicated QC team of 200+ inspectors applies AQL 2.5 / 4-point systems at final inspection. We welcome third-party audits from SGS, Bureau Veritas, and buyer-appointed inspectors.

  • 100% inline inspection + AQL 2.5 final audit
  • Metal detection & needle-break protocol
  • Measurement & workmanship spec check
  • Third-party (SGS / BV) audit ready
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08
Stage 08

Packing & Shipment

Buyer-specific packing instructions are strictly followed. Garments are packed, carton-marked, and loaded under CCTV-monitored conditions. ERP-driven export documentation ensures zero customs delay.

  • Buyer-specific polybag & hanger packing
  • Barcode scanning & carton check
  • On-time loading with GPS container tracking
  • ERP export documentation & LC compliance
What We Do Best

Core Manufacturing Capabilities

Six centres of excellence supporting diversified product categories and global buyer requirements.

Knit Garment Manufacturing

Specialised in single jersey, interlock, piqué, and french terry. Expertise across T-shirts, polo, activewear, and casual wear.

Single JerseyPiqué French TerryInterlock

Outerwear & Fleece

Outerwear capability including softshell, polar fleece, and windbreakers with taped seams and YKK zipper integration.

SoftshellPolar Fleece PaddingSeam Taping

Performance & Activewear

Moisture-wicking, UPF-rated, and compression garment production using recycled polyester and elastane blends for sport and athleisure markets.

Moisture-WickUPF-50+ Recycled PolyCompression

Loungewear & Sleepwear

Pyjama sets, nightgowns, and loungewear in woven and knit fabrics. Experienced with childrenswear nightwear compliance (BS 5722).

WovenKnit ChildrenswearBS 5722

Swimwear

Chlorine-resistant, four-way stretch swimwear production with flatlock seaming, bonded construction, and UPF-50+ fabric options.

4-Way StretchFlatlock BondedChlorine-Resist

Value-Added Services

In-house embroidery, screen printing, digital print, and garment washing services reduce lead time and protect IP with full design confidentiality.

EmbroideryScreen Print Digital PrintGarment Wash
By the Numbers

Factory Capacity & Scale

45+
Sewing Line
Gazipur
1,200+
Sewing Machines
JUKI, Brother, Pegasus & more
2.5 +
Milliion /Monthly
Capacity
34 +
Tons /Day
Dyeing Capacity
3,100+
Skilled Workforce
60% female employment
60
Days Lead Time
From PP approval to shipment
Zero Defect Culture

Quality Control Flow

Every garment passes through a structured, multi-checkpoint quality assurance system before it leaves our facility.

Fabric In-Spec
AQL on receipt
Cut Panel QC
100% count
Inline Check
Per operation
Measurement
Spec audit
Metal Detect
100% scan
Final AQL
2.5 standard
Packing Verify
Barcode scan
Shipment
Approved & dispatched
AQL Acceptance Standards Applied
Inspection Type Standard Defect Level Status
Fabric Incoming 4-Point System ≤ 28 pts / 100 yd² Accept
Semi-Final Inline AQL 2.5 Critical: 0 / Major: 2.5 Pass
Final Inspection AQL 2.5 Critical: 0 / Major: 2.5 / Minor: 4.0 Pass
Third-Party Audit Buyer-Specified As per buyer manual On Request
Infrastructure

Technology & Equipment

State-of-the-art machinery and digital systems power our 8 production units across Dhaka and Gazipur.

CAD / CAM System

Gerber and Lectra CAD for pattern making, grading, and marker planning — achieving up to 88% fabric efficiency.

Auto-Spreading Machines

Eastman and Morgan Tecnica auto-spreaders for consistent fabric layering and precise cut-to-spec production.

Specialised Sewing Units

1,200+ machines including flatlock, overlock, bartack, blind-stitch, button-hole, and eyelet for full garment construction.

In-House Laundry & Washing

Industrial washing, drying, and tumbling machines for enzyme wash, stone wash, pigment dye, and garment finishing.

ERP & Production Planning

Integrated ERP managing order tracking, production milestones, inventory, and export documentation in real time.

Metal Detection & Safety

All finished garments pass through metal detectors before packing. Needle-break log maintained per SMETA protocol.

Equipment Category Application
Single Needle L/S Machine General sewing operations
Overlock / Serger Seam finishing
Flatlock Machine Activewear & swimwear
Cover Stitch Hem & decoration
Button-Hole Machine Shirts & jackets
Embroidery Machine Logo & decorative work
Auto-Spreader Fabric laying
CAD / Plotter Pattern & marker planning
Partner With EFL

Ready to Start Your Next Order?

Send us your tech-pack or design brief and our merchandising team will respond with a detailed quote within 48 hours.

No MOQ on samples 48-hr quote turnaround Dedicated account manager