QC table with 200gsm coral fleece promotional blankets, measuring tape, GSM cutter, carton labels and inspection report

Define the inspection lot before choosing AQL

For AQL inspection of coral fleece promotional blankets, the first control point is the lot definition. One PO may include several colours, logo versions, folded formats, barcode labels or carton marks. If those variants are blended into one blind lot, a navy-only crocking issue or a wrong-logo colourway can be hidden by the total pass result.

A workable lot definition is: one PO, one SKU, one colour, one logo version and one packing configuration. If the buyer still wants a single PO-level accept/reject decision, the report should show sub-results by colour and SKU. This lets the buyer release conforming colourways while holding the failed portion for rework or replacement.

A typical 200gsm coral fleece promotional throw is 120 x 150 cm, 130 x 170 cm or 150 x 200 cm, made from 100% polyester knitted coral fleece at about 190-210gsm after brushing, shearing and heat setting. Pile height is often around 2.5-4.0 mm. Many cost-sensitive programs use 75D/144F or 100D/144F polyester filament; finer yarn gives a softer hand but is less forgiving if brushing is aggressive or heat setting stretches the fabric.

The PO must state finished size, target GSM, minimum GSM, colour standard, logo process, packing method, carton quantity, AQL levels and test requirements before bulk cutting. A line such as “200gsm coral fleece blanket, good quality” is not inspectable. For a broader factory QC framework, see our blanket quality control inspection guide.

AQL table and sampling rule

Use a named sampling standard, table edition and inspection level. A typical final random inspection instruction is: ANSI/ASQ Z1.4-2008 (R2018) or ISO 2859-1:1999, single sampling plan, normal inspection, General Inspection Level II for visual workmanship; critical defects 0 accepted; major defects AQL 2.5; minor defects AQL 4.0. If your inspection agency uses a different edition, reduced inspection, tightened inspection or switching rules, the accept/reject numbers must be confirmed from that table, not copied from a supplier checklist.

Under the above single-sampling, normal-inspection setup, a lot of 1,201-3,200 pieces normally reaches code letter K, sample size 125. At AQL 2.5 major, the table gives Ac 7 / Re 8. At AQL 4.0 minor, it gives Ac 10 / Re 11. A lot of 3,201-10,000 pieces normally reaches code letter L, sample size 200. At AQL 2.5 major, the table gives Ac 10 / Re 11. At AQL 4.0 minor, it gives Ac 14 / Re 15. Write the standard and table basis into the inspection booking because Ac/Re values are not a matter of factory preference.

Carton selection is separate from piece sampling. If 5,000 blankets are packed 20 pieces per export carton, the shipment has 250 cartons and the AQL sample is 200 pieces under code letter L. The inspector should select cartons across pallet positions, carton numbers, colours and production dates. A suggested commercial rule is to open at least the square root of total cartons when practical, so about 16 cartons from 250. This is not a statistical requirement in ANSI/ASQ Z1.4; it is a receiving-risk control and should be approved by the buyer.

Do not let the inspector pull only from the front pallet layer. The packing list should show carton number range by SKU and colour before inspection. The inspector then records the selected carton numbers, opens the selected cartons, checks every opened carton for quantity and marking, and draws enough pieces to reach the required sample size. If carton sampling destroys retail packing, agree the repacking and resealing method before inspection.

Separate visual inspection from lab testing

AQL visual inspection cannot prove restricted substances, fibre composition, flammability or long-term wash durability. It can find wrong labels, visible defects, poor packing and obvious workmanship failures. Lab and compliance testing must be specified separately with the test method, sample source, acceptance limit and responsibility for cost if retesting is needed.

Common blanket requirements include fibre content labelling, country-of-origin marking, care labelling, buyer barcode rules and retailer packaging rules. Care symbols and washing claims should match the fabric and decoration; a heat-transfer logo that cannot survive the stated wash cycle creates a claim risk. For practical care instruction choices, see our blanket care washing guide.

Chemical compliance depends on destination and product category. EU buyers may request REACH-related declarations and restricted substance testing. US buyers may request CPSIA checks for children’s products and Prop 65 assessment where relevant. Some buyers request OEKO-TEX Standard 100 documentation for skin-contact textiles; the exact class and scope should match the end use, not be assumed from a fabric swatch. See textile certifications explained for buyers and OEKO-TEX Standard 100 for custom fleece blankets for procurement context.

Flammability rules also depend on market and use. A general promotional throw is not the same as an airline blanket, a children’s sleep product or a contract hospitality item. If flammability is mandatory for the program, state the exact regulation or buyer protocol and do not treat a normal AQL inspection as evidence of compliance.

Defect classification for coral fleece blankets

Defect classes must reflect commercial risk. Critical defects create safety, legal or severe compliance risk. Examples include metal contamination, broken needle fragments, mould, live insects, sharp foreign matter, missing legally required fibre or care label where applicable, and a product packed for children with unsafe small detachable parts or non-compliant labelling. Critical defects are normally accepted at zero; one finding usually puts the lot on hold for 100% screening and root-cause review.

Major defects make the blanket unsellable, unfit for campaign use or clearly different from the approved sample. For 200gsm coral fleece, major defects include wrong size outside tolerance, GSM below agreed minimum, wrong colour outside approved shade band, missing or reversed logo, logo placement outside tolerance, embroidery holes, heat-transfer cracking or lifting, fabric holes, obvious oil stain in a visible zone, open seam, exposed raw edge, severe pile crush, mixed colours in one polybag, missing buyer hangtag, wrong carton quantity or wrong shipping mark.

Minor defects are visible but not normally return-causing if isolated. Examples include a loose thread under the agreed limit, removable lint, slight nap-direction shade, small label skew within tolerance, mild fold inconsistency, minor carton scuff without product damage and local stitch density variation that does not weaken the seam. Minor defects still matter because a high count makes the shipment look cheap even when major AQL passes.

Suggested commercial thresholds must be buyer-approved. An oil stain over 5 mm in a visible area, an open seam over 20 mm, a loose thread over 30 mm or a diagonal skew of 2-4 cm may be reasonable for many promotional programs, but they are not universal standards. Retail gift packs, charity tenders, airline kits and children’s products often need tighter rules. Put the thresholds in the inspection protocol so the factory, buyer and inspector judge the same way.

Our in-mill defect examples include pile-crush rectangles from over-compressed cartons, shiny bands from uneven heat-setting tension, corner dog-ears from rushed folding, overlock chain tails trapped into the polybag seal, and embroidery puckering caused by using dense satin stitches on light 200gsm fleece. These are easier to prevent inline than to rework after packing.

GSM acceptance rules

GSM must be written as target, individual minimum and lot average. A practical PO rule for a 200gsm coral fleece promotion is: target 200gsm after finishing; individual specimen not below 190gsm; colour-lot average 195-210gsm; no approved bulk colour may average more than 5gsm below the approved pre-production sample unless accepted by the buyer. If the buyer wants “minimum 200gsm,” say so clearly and expect higher yarn input cost.

Condition the samples before weighing when possible. Use ISO 139 standard atmosphere where lab testing is required, typically 20 ±2°C and 65 ±4% relative humidity. For factory inspection, allow the opened blanket to relax away from direct steam, rain or warehouse condensation before cutting specimens. Moisture and packing compression can move readings enough to start avoidable disputes.

Use a controlled specimen method. Reference ISO 3801 or ASTM D3776 where accepted by the buyer. Cut 100 cm² specimens with a calibrated GSM cutter and weigh on a calibrated electronic balance readable to 0.01 g. Avoid edges, seams, labels, embroidery, embossed areas, printed zones, heavy nap lines and visibly stretched corners. For each inspected colour, cut at least three specimens from one blanket, or preferably one specimen from each of three blankets. Record every reading, not only the average.

Panel location matters on fleece. Readings from the centre can differ from edge zones because knitting tension, brushing pressure and heat setting are not perfectly uniform. A useful field pattern is one specimen from upper-left body, one from centre body and one from lower-right body, all away from seams. If colourways differ, report each colour separately; dark disperse dyes, cationic effects or different finishing lots can change hand-feel and apparent thickness even when yarn input is similar.

If one colour fails GSM while the total PO average passes, do not average it away. Hold that colourway, verify retained fabric roll records and finished-piece readings, and agree whether to replace, discount, relabel, or release with written buyer concession. The passing colours can be released only if packing and distribution allow physical separation by carton number.

Size, skew, seams and logo tolerances

Measure size without tension. Lay the blanket flat for at least 30 seconds, smooth major wrinkles by hand and measure finished edge to finished edge with a calibrated steel tape or measuring table. For a 120 x 150 cm 200gsm fleece throw, ±3 cm in length and width is a common commercial tolerance. For stricter retail presentation, use ±2 cm. For large 150 x 200 cm throws, ±3% may be more realistic than a fixed centimetre rule unless the factory cuts with extra allowance and accepts higher waste.

Measure multiple points. Width should be taken near the top, centre and bottom; length should be taken at left, centre and right. Record the average and worst reading. Check diagonals on at least five pieces per colour. A suggested commercial diagonal difference is within 2-4 cm depending on size; this catches twisting that may not appear in simple length and width readings. State the exact tolerance on the PO.

Seam and edge construction should be measurable. For overlocked coral fleece, specify 3-thread or 4-thread overlock, stitch density, seam allowance and chain-tail trimming. A practical target is 8-12 stitches per 2.5 cm, no skipped chain over 10 mm, no exposed raw edge wider than 2 mm, and seam allowance not less than the approved sample. Bound edges should be checked for finished binding width at three points per side and caught stitching through all layers.

Logo tolerances need coordinates, not words. Example: embroidered logo 80 x 35 mm, placed 120 mm from bottom finished edge and 120 mm from right finished edge to logo centre; placement tolerance ±8 mm; rotation or skew within 3°; size tolerance ±3 mm; no visible puckering beyond approved sample. For a larger chest or corner print, use a paper template or measurement jig during inspection.

Decoration checks depend on method. Embroidery should match approved thread colour or Pantone reference as closely as the thread range allows, with buyer-approved stitch density, backing type and no needle cutting. Heat-transfer logos should show no edge lifting after a tape pull or fingernail check agreed by the buyer, no cracking after folding, and no obvious colour migration from dark fleece. Printed logos should be checked for colour deviation against approved standard, commonly using a grey scale or spectrophotometer target if the buyer specifies one. Rub and wash checks should be separate from AQL unless the buyer defines them as inspection tests.

For alternative decoration methods and their failure modes, see custom blanket decoration methods. If the order uses navy or dark fleece, consider crocking risk controls similar to those in AATCC 8 crocking standards for navy sherpa blankets, adapted to the actual fabric and dye route.

Carton and packing checklist

Promotional blanket failures often happen after sewing. A blanket can pass hand-feel, size and logo checks but still fail distribution if carton quantity, barcode, colour ratio, polybag warning, carton cube or shipping mark is wrong. Packing requirements should be locked before bulk folding starts, not negotiated at final inspection.

For 120 x 150 cm 200gsm coral fleece, a master carton often holds about 20-30 pieces depending on fold, polybag and compression. For 150 x 200 cm, 12-20 pieces is more realistic. Higher compression reduces CBM but can create pile-crush lines, distorted folded edges and barcode scanning problems if labels wrinkle. If the buyer needs fast shelf recovery, limit compression and approve a folded-size range.

Carton checks should include: carton dimensions within ±2 cm unless buyer specifies tighter; gross weight within ±5% or agreed tolerance; correct carton sequence; PO, SKU, colour, quantity and destination marks matching approval; no unauthorised mixed SKU; readable barcode; correct inner quantity; correct retail pack contents; intact tape; no wet, crushed, mouldy or oil-stained cartons; desiccant only if specified and safe for the destination requirements.

Every opened carton should be checked for quantity and marking. At least 20 retail packs per SKU or all opened-carton retail packs, whichever is practical, should be checked for barcode, warning text, care label visibility and assortment. If a club retailer, Amazon route, airline caterer or NGO warehouse provides a carton label format, reproduce it exactly. “Standard export carton” is not enough for controlled receiving.

Buyer PO clause block

Use a clause block that the factory, inspector and buyer can all apply. The wording below is a practical template and should be adjusted for destination law, buyer risk level and inspection agency procedure.

PO inspection clause: Lot definition: each PO/SKU/colour/logo version/packing configuration inspected and reported separately. Sampling standard: ANSI/ASQ Z1.4-2008 (R2018) or ISO 2859-1:1999, single sampling, normal inspection, General Inspection Level II for visual workmanship unless otherwise agreed in writing. AQL: critical 0 accepted; major 2.5; minor 4.0. Carton sampling: inspector to select cartons randomly across carton number range, pallet position, colour and production date; open at least enough cartons to draw the required piece sample and at least square root of total cartons where practical, unless packing damage risk is agreed in advance.

Size and GSM clause: finished size 120 x 150 cm, tolerance ±3 cm length and width unless size table states otherwise; diagonal difference maximum 3 cm; GSM target 200gsm after finishing; individual 100 cm² specimen not below 190gsm; colour-lot average 195-210gsm; specimens cut away from seams, labels, logos and edge zones using ISO 3801 or ASTM D3776 principle; readings recorded by colour.

Logo clause: artwork, size, colour and placement to approved pre-production sample and artwork file; logo centre position tolerance ±8 mm from approved coordinates; rotation maximum 3°; logo size tolerance ±3 mm; embroidery thread to approved shade card; heat-transfer or print must show no lifting, cracking, bleeding or obvious colour deviation against approved standard; wash/rub testing only valid when performed to the buyer-specified method.

Defect and reinspection clause: defect classification follows approved inspection checklist. Failed lot or failed colourway may be reworked, replaced, downgraded or shipped only by written buyer concession. Reinspection after rework is at supplier cost unless failure is caused by buyer-approved specification change. Reworked cartons must be identifiable by carton number and reinspection date. No blending of failed and passed colourways without buyer approval.

Worked inspection example

PO: 5,000 pieces of 120 x 150 cm 200gsm coral fleece promotional blankets, packed 20 pieces per carton, total 250 cartons. Colours: navy 2,000 pieces, grey 2,000 pieces, ivory 1,000 pieces. Logo: corner embroidery. Sampling instruction: ANSI/ASQ Z1.4-2008 (R2018), normal single sampling, General II, critical 0, major AQL 2.5, minor AQL 4.0. Lot size 5,000 gives code letter L and sample size 200. Major Ac/Re is 10/11; minor Ac/Re is 14/15 under that table.

The inspector selects 16 cartons across the full carton range, including at least six navy, six grey and four ivory cartons because the colour quantities are uneven. From the opened cartons, the inspector draws 200 pieces proportionally: 80 navy, 80 grey and 40 ivory. All opened cartons are checked for carton marks, quantity and barcode. GSM is checked separately on three pieces per colour with three 100 cm² readings per colour.

Findings: total visual defects are 9 major and 11 minor, so the total PO numerically passes AQL 2.5 major and AQL 4.0 minor. However, 7 of the 9 major defects are navy logo-placement failures, with logos 18-25 mm outside the approved corner coordinate. Navy GSM average is also 192gsm with one specimen at 188gsm, while grey and ivory are within the agreed range.

Decision: do not release the full PO simply because the combined AQL count passes. The navy colourway shows a concentrated process failure and a GSM nonconformity. Hold navy cartons by carton number, review embroidery jig setup and fabric roll records, then rework or replace the navy portion. Grey and ivory may be released only if their carton numbers, packing list and shipment plan allow clean separation. If the buyer needs full campaign colour balance, the commercial decision may still be to hold the entire shipment until navy is corrected.

This example prevents a common dispute: the factory argues that the PO passed numerically, while the buyer sees one colourway that will fail at distribution. The inspection protocol should state whether sub-lot failure overrides PO-level pass. For promotional programs, we recommend it does whenever the defect is colour-, logo- or SKU-specific and commercially material.

Rework versus rejection decision tree

Use a simple decision tree before arguing over discount. First, identify whether the defect is safety/compliance, functional, cosmetic or packing-related. Safety and legal defects normally require hold, root cause and 100% screening or replacement. Functional defects such as open seams, weak binding, missing labels or low GSM may be reworkable only if the rework can be verified without damaging the product.

Second, check whether the defect is local or systemic. One loose thread can be trimmed. A repeated overlock skip on one production line needs line segregation and 100% edge screening. One wrong carton mark can be relabelled. A wrong barcode printed on every retail sticker may require full repacking and buyer approval because downstream receiving data is affected.

Third, confirm whether rework changes appearance. Removing embroidery, reheating a transfer print or opening compressed polybags can leave marks. Rework that technically fixes the defect but leaves visible damage should be classified again after rework, not assumed acceptable.

Fourth, define the reinspection scope. If only navy logo placement failed, reinspect navy logo placement, navy GSM and any packing disturbed during rework. Do not charge the buyer for rechecking grey and ivory unless they were touched or the buyer requests a full new inspection.

Frequently asked

Is AQL 2.5 strict enough for 200gsm coral fleece promotional blankets? For many low- to mid-value promotional programs, major AQL 2.5 and minor AQL 4.0 is a workable commercial balance. Premium retail, airline, children’s or tender orders may need major AQL 1.5, tighter minor limits or additional lab testing. The AQL level should match the return risk and distribution channel.

Can one failed colourway be rejected if the total PO passes AQL? Yes, if the inspection protocol defines colourways as reportable sub-lots or states that concentrated SKU, colour or logo failures override the combined PO result. This is recommended because colour-specific dye, GSM, crocking or logo-jig problems are not fairly represented by a blended total count.

What GSM tolerance should I use for a 200gsm coral fleece blanket? A practical rule is 200gsm target, no individual 100 cm² specimen below 190gsm, and colour-lot average 195-210gsm after finishing. Buyers wanting true minimum 200gsm should state “minimum 200gsm” and expect higher material cost. GSM readings should be recorded by colour and specimen location.

Should GSM cutting be part of the AQL sample of 200 pieces? No. GSM cutting is destructive and should use a smaller controlled sample, often three pieces per colour with three specimens per colour, unless the buyer requires more. Visual AQL sampling and GSM verification should be reported separately.

What logo tolerances are reasonable for a corner embroidery on fleece? For many promotional throws, placement tolerance of ±8-10 mm from approved coordinates, rotation within 3°, and logo size tolerance of ±3 mm are practical. High-visibility retail packs may need tighter limits. The approved sample and artwork file should control thread colour, density, backing and puckering.

Does passing AQL prove REACH, Prop 65, OEKO-TEX or flammability compliance? No. AQL inspection is a sampling method for visible workmanship and packing defects. Chemical compliance, flammability and certification claims require separate documents and lab tests using the buyer-specified standard, sample source and acceptance criteria.

Have a project in mind? Send us your spec — we'll reply within one business day with indicative pricing and a sample plan.

Related