|A-Sky Clothing Co. Ltd|
Guangdong-based A-Sky produces midrange denim
jeans, jackets and skirts mainly for US fashion
buyers such as Apollo. In-house production
facilities involve sewing and finishing. Garment
washing, fabric weaving and component manufacture
are subcontracted to other factories.
This private, locally owned company employs 850
workers who produce an average 150,000 denim
garments each month. 70 percent of this total is
shipped to the United States and the rest to Eastern
Europe, the Middle East and Asia.
Located in Xintang town in Guangzhou, Guangdong
province, A-Sky benefits from convenient access to
materials and components, as Xintang is one of the
four key production hubs for denim garments.
Denim jeans account for 80 percent of total output,
and are priced between US$5 and US$6 FOB. Lower
priced jeans are made of handbrushed pure cotton
with enzyme or monkey wash. Higher priced jeans are
made of linen and cotton blends with other washes
and finishes such as whiskering, grinding,
embroidery and beading.
Each pair of jeans comes with a belt, which is
offered in retail shops as a free gift with the
garment. However, since the factory's production net
margin is as low as 10 to 20 cents, the belt adds US
50 cents to US$1 to the price of a pair of jeans.
The belts are made of wood or silk fabrics and
embellished with beads or rhinestones.
Denim jackets are priced between US$6 and US$7,
and miniskirts at US$4.50. A-Sky has not raised
product prices despite higher operating costs to
A-Sky's in-house R&D team includes two designers
and 29 sample makers. The designers use CAD systems
to create new product patterns based on buyers'
Women's denim garments are made of fabrics that
contain 1 to 4 percent spandex fibers. To avoid
quota restrictions, all skirts and some jeans are
blended with 55 percent linen.
Most denim fabrics are sourced from local
suppliers and only a small portion is imported.
Components and parts such as zippers, tapes and
buttons are sourced locally as well.
A-Sky's sewing lines have four fabric-cutting beds
and 480 sewing machines in various types and
functions. The finishing lines have sandblasting
machines and handbrushers.
In-house production procedures involve fabric
preshrinking test and cutting, garment sewing,
finishing and packaging. Embroidery and printing are
subcontracted. Delivery is within 30 days, inclusive
of fabric weaving.
Garment washing is subcontracted to local
factories. The combination of in-house facilities
and subcontracting allows the company to offer
various washes and finishes including enzyme,
whisker, monkey, dirty and chemical washes, as well
as grinding and sandblasting.
The charge for enzyme washing starts at US 36
cents per piece. An additional US 24 cents is
charged for both monkey wash and handbrushing.
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