How long does it take to make men's underwear? – Tani USA

How long does it take to make men's underwear?


What goes into Tani underwear before you do?

Tani USA Tani Underwear Tani Apparel 

It takes about one year for new Tani underwear collection to go from the drawing board to the sales floor. At Tani USA, we design and fabricate our own underwear. Unlike most major brands, Tani owns and operates its own R&D and Manufacturing facility. This allows us to oversee the entire process from design inspiration to product innovation. 

 Tani Manufacturing

(Tani USA manufacturing and housing facilities)

It might sound crazy but it actually takes 12 months to develop a new pair of underwear. While we are always on the lookout, we start dedicated research one year out. Basically it’s, Research. Research. Research. And then some more research. Our R&D team and designers scour the planet for the best fabric innovations and meet with fabric and fiber suppliers to brainstorm new materials, finishes and innovations. We also review color and design trends, and hit every fabric trade show for latest advancements.

Fabric innovation 
(Above high gauge micro knitting machines in Austria)

9 months to go: Planning the collection. Storyboard the seasonal themes and design prototypes.

6 months to go: Produce samples for internal and external review. Wash and stress test underwear samples. Photography, sales, marketing and advertising developed.

5 months to go: Final revision of underwear specifications based on results of testing. Pre-production to coordinate the highly complex process of fabricating, sewing, and finishing of Tani clothing and underwear.

2 months to go: All fabrics and accessories delivered are inspected for quality and color. Samples are produced and reviewed for quality, fit and finish. Fabrics are hand spread and relaxed for 48 hours.

(Fabrics are stored prior to inspection)
(Fabrics are spread and inspected prior to relaxing)
 
45 days to go: Production is GO! The excitement ramps up as our factory goes full steam ahead. With over 150 employees hand cutting fabrics. Fabrics are inspected for the final time for color and for any possible defects.
Tani employees cutting fabric for production
(Fabrics are cut using small piles.  Most brands cut through 12"+ fabric to speed through the process.  We use only 2" high piles to ensure cutting accuracy.  This allows for an extremely consistent fit.)

30 days to go: Sewing begins. An intricate ballet of coordination and a 12-step process for men’s underwear alone.

 

 

1 week to go: Final inspection.

Ship: Everything is ironed and packed, ready to ship and ready to wear.