AQL (Acceptable Quality Limit) is the internationally standardised method for textile pre-shipment inspection, governed by ISO 2859-1 (ANSI/ASQ Z1.4) at General Inspection Level II — the industry default for retail and hospitality programmes. For a 5,000-piece shipment, 200 units are randomly inspected; the lot FAILS if more than 10 major defects (AQL 2.5) or more than 14 minor defects (AQL 4.0) are found; zero critical defects are accepted regardless of lot size. The AQL inspection report — stating the standard, sample size, defect counts by class and a PASS or FAIL result — is the commercial document that authorises or blocks shipment release.
The Three Defect Classes
| Class | Definition | Standard AQL | Examples |
|---|---|---|---|
| Critical | Unsafe, illegal or unusable; blocks sale | 0 — zero tolerance | Broken needle in garment, mould, failed flammability label |
| Major | Likely to cause a return or complaint | 2.5 | Open seam, visible stain, hole, wrong size label, shade variation |
| Minor | Workmanship flaw a customer may not notice | 4.0 | Untrimmed thread, slightly skewed label, light crease |
AQL 2.5/4.0 is the common standard for retail apparel and home textiles. Premium programs sometimes specify 1.5/2.5; institutional or promotional goods sometimes accept 4.0/6.5. The buyer's specification always overrides the default.
Sample Size: How Many Pieces Get Inspected
The sample size depends only on the lot size (total units in the shipment). Under Level II, the most-used rows are:
| Lot size (pcs) | Sample size | Major 2.5 — Accept / Reject | Minor 4.0 — Accept / Reject |
|---|---|---|---|
| 281 – 500 | 50 | 3 / 4 | 5 / 6 |
| 501 – 1,200 | 80 | 5 / 6 | 7 / 8 |
| 1,201 – 3,200 | 125 | 7 / 8 | 10 / 11 |
| 3,201 – 10,000 | 200 | 10 / 11 | 14 / 15 |
| 10,001 – 35,000 | 315 | 14 / 15 | 21 / 22 |
Reading the table: for a 5,000-piece shipment, the inspector randomly pulls 200 pieces from across the packed cartons. If 10 or fewer major defects are found, the lot passes on majors; at 11 it fails. Critical defects are always 0-accept regardless of lot size.
What a Final Random Inspection Actually Covers
- Quantity and assortment — carton count, size/colour ratio against the packing list
- Workmanship — every sampled piece checked inside and out against the defect list
- Measurements — a measurement sub-sample checked against the size chart and tolerances
- Colour — bulk shade compared with the approved lap dip / PP sample under a lightbox
- Packing & labelling — polybag, hangtags, carton markings, barcode scans
- On-site tests — seam strength pull, stitch density count, GSM cut where applicable
Reading the Inspection Report
A proper report states the standard used (ISO 2859-1, Level II), the AQL values, the lot and sample size, defect counts per class with photographs, measurement tables, and an overall result: PASS, FAIL, or PENDING (when a non-defect issue such as missing shipping marks needs correction). Never accept a verbal 'it passed' — the report is your evidence in any later claim.
If the Inspection Fails
- 1The factory sorts and reworks the order — 100% screening of the failed defect type, then re-inspection (typically at the factory's cost).
- 2You negotiate — accept with a documented discount if the defect is cosmetic and your market tolerates it.
- 3You reject — rare, but the AQL report is what makes the rejection commercially enforceable.
Common pitfall: inspecting too early. Final random inspection requires at least 80% of the order packed in final cartons. An inspection on 50% packed goods is a 'during production' check, not a basis for shipment release.
For every order placed through MZ Global Trading, third-party pre-shipment inspection is arranged as standard — see how we handle it on our inspection process page. Specify your AQL level and inspection requirements upfront in the sourcing RFQ form.
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Disclaimer: This content is provided for general information only and does not constitute legal, customs or compliance advice. Always verify requirements against your buyer specification, applicable regulations and your destination market before making commercial decisions.