Behind the Seams: The Craftsmanship of Quartz Co. Coats
Text by: Quartz Co.
All winter coats from Quartz Co.'s Heritage collection—our bestsellers—are made in Quebec. Join us behind the scenes of their creation, from design to final assembly, at our bustling Montreal factory.
DURABLE AND INCLUSIVE DESIGN
The process begins with a drawing—a product designed by humans for humans, aiming to protect against natural elements while being environmentally conscious. Our skilled product development team combines years of expertise in design, textile research, and sustainable sourcing to create the best possible product. At our Montreal design studio, we craft timeless, durable, and functional styles with various cuts, lengths, and features to cater to a wide range of tastes, needs, and body types.
PROTOTYPING
Even though our Heritage collection's extreme winter coats - like Ines, Chloé, Genia, Labrador, Champlain, Vostok, and others - are customer favorites, we continuously refine their designs so that they better adapt to your reality. When a change is made, a prototype is produced in our factory approximately 12 to 18 months before the model hits the stores. This allows us to test and evaluate its look, fit, comfort, and performance before production begins.
COAT PRODUCTION
Every year, the new season's models arrive in stores during the month of September. The production period, therefore, begins as early as January, eight months prior, following this process as explained by Marie-Hélène, the production manager at Montreal’s factory.
STEP 1: CUTTING
- The product development team provides the technical documents and detailed patterns of the models, which will be used throughout the entire process.
- Nicolae, the head of the cutting room, handles grading, which means adjusting the original pattern to create all the sizes offered, following the standards established over the years at Quartz Co.
- Next, the textiles are cut using markers, meaning all the pattern pieces for a given fabric are printed and arranged like a game of Tetris.
STEP 2: SEPARATION
- The pieces are separated, and the accessories are prepared, operation by operation. “At the factory, production works in a serpentine flow, by blocks,” explains Marie-Hélène. “Each block corresponds to a specific operation, which is always performed by the same operator to ensure consistency, precision, and efficient workflow.”
STEP 3: ASSEMBLY
- The assembly of a coat begins with preparing the visors, pockets, flaps—the piece that covers the zipper—sleeves, and hood.
- The coat’s lining is handled simultaneously. The isolated pieces are prepared with down or synthetic insulation, and they are assembled to form the entire interior of the coat. Then comes the filling stage. “The down we use arrives at the factory compressed in bags. To fluff it up, it’s passed in a machine—the distributor—which, through a rotating motion, allows the down to expand and reach its full loft. The distributor is then programmed to inject the exact amount of down into each part of the coat; this amount is previously determined by the development team, considering the desired warmth and overall look.
- Once all the coat’s elements are ready, they are attached together. The process begins by attaching the pockets, followed by the shoulders, hood, zippers, flaps (depending on the model), and sleeves. Finally, the shell—the outer layer—is assembled.
- The lining is then joined with the coat’s shell. “Then the coat is turned right-side out, as the lining and shell are always assembled inside out.”
- To finish, the coat is ‘closed’ and the final touches are applied: final topstitching and snap buttons.
LAST STEP: INSPECTION, LABELING, AND PACKAGING
We ensure that the product meets the specifications described in the technical documents and that it complies with all our high-quality standards. Every snap button, zipper, and seam is inspected and tested throughout the process and at the end of assembly. “Since it's a chain manufacturing process, a mistake at one stage compromises the next, which is why each step is inspected. We must be constantly attentive to details, even if they seem minor,' summarizes Marie-Hélène. 'This year, we have 14 coat models to produce in multiple copies, as well as the Trapper hat.' Finally, we trim the final threads, add the labels, fold the coats, and slip them into bags.
GOOD TO KNOW
The most delicate step? “There are several,” explains Marie-Hélène. “When we attach zippers to a quilted coat with topstitching, it’s crucial that the alignment is perfect. The pockets are also delicate, especially if they have welts, because great precision is needed to avoid a crease or even a hole. As for the flap, it must be impeccably placed, as it’s one of the first things you see on the coat, right at the front.” And what about the down filling? The distributor must always be perfectly calibrated to ensure that the amount of down inserted into each piece is precisely accurate, so that every coat provides an optimal level of warmth. No detail is overlooked at Quartz Co.
If you have any questions about our coat manufacturing process, please contact our team—we’re happy to help.