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Production Sampling and the Green Quadrant

Production Sampling and the Green Quadrant. Selected Excerpts From 2009 AATCC Conference Dan Randall Colorways 3/11/2009. 2009 Color of the Year. +b*. -a*. +a*. -b*. Color Technologies that Save Money and the Planet. Shade Bands with fewer Hands The $15 Sample Garment

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Production Sampling and the Green Quadrant

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  1. Production Sampling and the Green Quadrant Selected ExcerptsFrom 2009 AATCC ConferenceDan RandallColorways 3/11/2009

  2. 2009 Color of the Year

  3. +b* -a* +a* -b*

  4. Color Technologies thatSave Money and the Planet • Shade Bands with fewer Hands • The $15 Sample Garment • Virtual QC Check at the DC

  5. Memories of Charleston • Number of lab dips produced per year for Retail/Brand companies in the USA: 5,475,398 • Cost of producing these dips: • $481,835,024 • Cost of sending by courier: >$20,000,000 • Dips 5,475,398 x 4” size = 345 miles of dips end to end.

  6. 1 – Retailer A Production Sampling • <2002 All SBs were sampled and expedited to Retailer’s Offices • 2002-Present: Shift from Physical to Electronic Sampling /1000

  7. From Physical to Electronic

  8. SBE Process Images courtesy of

  9. 2008 Shade Band results • Total SBs tested: 104,529 • Total Approved: 82,769 (~80% passing) • SB Physicals : 22,250 • SBs not requiring physicals: 82,279 • Savings in shipping costs: $2.9M

  10. 2002-Present • Shade Bands – Electronic: 464,200 • Saving to Suppliers, shipping: $16.3M • Lab Dips • 9,500 /month = 114,000 / year • 40% electronic = 45,600 • Savings in shipping cost: $1.6M • Total Cost Savings in Shipping: $27.5M

  11. 2 - The $15 Sample Garment • Lifesize • Color Accurate • Realistic Did I mention they are printed on paper?

  12. Visualize the collection

  13. Garment Mapping With just one suitable plain ‘donor’ garment …… and a pattern repeat in an electronic file…… or Stripe dimensions…. and the required shades…….

  14. Virtual Garments, Savings in.. Time-consuming Admin. Transporting Samples Making-up into garments Slides courtesy of

  15. 3 - Virtual QC Check at the DC • Sampling garments that are not measurable • Denim, prints, for example

  16. Communicating Quality Photos courtesy of

  17. Environmental Benefits • Difficult to calculate exactly • Approximate by • Shipping Process • Fuel Consumption • GHG (CO2) output

  18. One Package from Suzhou All maps by GoogleEarth

  19. One Package from Suzhou • Shanghai to Anchorage • 4,331 miles • 8.75 hrs • 8,500 gal Fuel

  20. One Package from Suzhou • Anchorage to Memphis Superhub • 3,142 miles • 6.25 hrs • 4,700 gal Fuel

  21. One Package from Suzhou • Memphis to Tulsa • 411 miles • 0.9 hrs • 675 gal Fuel • Tulsa to Retailer • 101 miles, Truck • 7 MPG = 14.4 gal

  22. One Package from Suzhou • Total: 8,035 miles • Fuel Consumption: • 13,889 gallons • 4.6B gallons annually for shipping • 2.5B US deliveries • 2.4B Tons CO2 from US deliveries

  23. Just ask yourself…. • Do I really need that 3rd Lab Dip? • Do I really need to dip every color in the palette? • Am I working toward digital color processes that reduce physical sampling?

  24. We thank you And the Planet Thanks you

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