If you’re looking to manufacture custom plush toys, stuffed toys, stuffed animals, or dolls, understanding the sampling production process is key. From developing a tech pack and understanding sampling to shipping your order, here’s everything you need to know about manufacturing toys with Purnaa.
Product Development – Creating Custom Toys and Dolls
What should I include in my toy tech pack?
A well-structured toy tech pack ensures your design is accurately produced. Here’s what to include:
Bill of Materials (BoM): A list of all fabrics and trims, such as:
Main fabric
Trim fabric
Stuffing
Labels
Hangtags
Embroidery options for facial features (machine or hand-embroidered)
Measurements & Diagrams: Uniform measurements (inches or centimeters) with detailed diagrams.
Facial Features & Details: Since facial features define a plush toy, stuffed toy, or doll, providing clear instructions and reference images is crucial. Note Human vs. Animal Dolls: Human dolls are more complex. If you’re designing a human doll, detailed patterns and tech packs will make the process smoother.
Reference Samples: If you have physical samples or patterns, you may not need a full tech pack. Purnaa can assist in developing a tech pack if you have a sample or images of your concept.
I have a doll or stuffed toy design, but it needs modifications. Can Purnaa help me?
Yes. Our expert project managers can help modify your existing design. Providing clear reference images and specific editing instructions will streamline the process.
Sampling – What You Need to Know
How long does sampling take?
Sampling lead times vary based on your preparedness, responsiveness, and our team’s sample schedule. Typically, the process takes around 12 weeks from first contact to receiving your sample.
I have a concept but no tech pack or patterns – Can Purnaa develop my toys and dolls?
Yes! We offer different sampling packages based on your needs:
Production-Prep Package – You have a prototype, pattern, and materials, and need a sample sewn.
Production-Prep + Sourcing Package – You have a prototype and pattern but need us to source materials and sew a sample.
Full Product Development Package – You have design specifications, and we source materials, create a pattern, and develop a sample.
Find more details in our Sampling Need-to-Know Document.
Order Details
What is the MOQ for Plush Toys, Stuffed Animals, and Dolls?
Minimum Order Quantities (MOQs) depend on the type of doll (knit, crochet, or sewn). Our typical MOQ is 500 pieces per style, this is to ensure that we can guarantee at least 5 days of work from each order for our production teams. For more complex designs our MOQ is flexible. Get in touch to find out what the MOQs are for your order.
What is the standard lead time for manufacturing dolls and toys?
At Purnaa, plush toy and stuffed toy production takes on average between 3-4 months, with 6-8 weeks allocated to material sourcing and the remainder to manufacturing.
Tip: Raise your Purchase Order (PO) early to secure a priority spot in the production queue.
Fabric, Materials, and Trims
What fabric options does Purnaa offer for toys and dolls?
We source high-quality materials from reliable suppliers we have developed long-term relationships with, these materials include:
Organic cotton fleece and jersey
Recycled polyester fleece and jersey
Standard cotton fleece and jersey
Organic cotton yarn
Other specialty materials including, merino wool can be sourced from suppliers depending on the MOQ. We keep recycled polyester fleece in stock.
Do you offer custom material/yarn color options?
Yes, custom color options are available if the order quantity meets the supplier’s minimum order quantity (MOQ) for the fabric or yarn. Most suppliers can match colors based on the customer’s specifications. To ensure accuracy, customers need to provide a Pantone color code for reference.
Can Purnaa manufacture toys using 100% natural materials ?
We can provide natural fabric, stuffing, and thread options.
What stuffing options are available for Toys/Dolls?
🌱 Kapok: Natural, lightweight, and biodegradable.
☁️ Cotton Fill: Available in organic and non-organic varieties.
✨ Polyfill: A synthetic, cost-effective stuffing widely used for plush toys. New or recycled options are available.
Can I provide my own fabric for production?
Yes, in some cases, customers may supply their own fabric for production. The most efficient approach is for Purnaa to purchase the fabric directly from your supplier, with the cost added to your order.
If you already have the fabric on hand, Nepalese Customs Law requires Purnaa to account for it as a purchase. In this case, you would need to issue an invoice reflecting the transaction so we can comply with customs regulations.
For a smooth process, we recommend discussing your fabric sourcing needs with us in advance to ensure compliance and minimize any potential customs fees.
What labels and hangtags should I use for toys?
Woven Label: Includes country of origin and material composition (mandatory in many countries).
Fire Warning Label: Required in some regions.
Hangtag: Optional but great for branding. Many size and material options available.
Quality, Testing, and Standards
What are the quality requirements for toys and dolls?
Quality control is crucial. At Purnaa, we follow 100% in-line QC checking, meaning every stage of production is inspected and a final QC check is completed on all products before they are shipped.
What are the legal testing requirements for children’s products?
Regulations vary by country. We work with your team to support your specific test and regulatory requirements to ensure compliance with required safety standards. For testing we work with reliable testing labs in India, China, the US and Europe. We can make samples for lab testing at your specified lab, or we can help you select a lab suitable for your specific requirements.
Are my toys Fair Trade?
Yes, all products made at Purnaa are Fair Trade, as we operate within a WFTO Fair Trade guaranteed factory. However, if you wish to display the Fair Trade logo on your products, you will need to pay a licensing fee, which is calculated as a percentage of the order value. This fee is paid directly to the World Fair Trade Organization (WFTO). Our team can guide you through the process if you’d like to include the certification on your products.
Shipping and logistics
How should I package my plush toys and dolls?
When deciding on how you want your product to be packaged. It’s important to consider where your toys will be shipped from, and what the most cost effective options are for shipping goods? Options include:
Individual packaging (ready-to-sell)
Multi-packed (for warehouse repackaging)
Vacuum-packed
If you have a clear vision for how you want your toys to be packaged, please provide details in your tech pack.
How does Purnaa ship products?
As Nepal is a landlocked country, all shipments are typically air-freighted for efficiency and reliability. While there is an option to transport goods by road to the nearest port in India, this route often comes with delays and logistical risks. To ensure timely delivery, we recommend air freight, and our team can provide tips on optimizing costs—such as reducing volumetric weight—to make shipping more affordable.
What should I know about the shipping process?
Shipping costs are determined based on both actual weight and volumetric weight (size-based weight). Some customers assume that lightweight products, such as dolls, will have low shipping costs. However, because of their size, these items may be charged based on volumetric weight. In such cases, using vacuum packaging can help reduce shipping costs.
If you plan to ship fabrics and materials to Purnaa for production, please note that Nepal Customs regulations do not allow the import of cut-piece fabrics. Fabrics must be imported as rolls or in large, continuous lengths. Even if not in roll form, they should appear as sizable fabric pieces rather than small cut sections.
Do's and Dont's of Toy Sampling & Production
DO:
✔ Share a detailed tech pack with precise measurements, material details, and reference images.
✔ Confirm safety standards early in the process.
✔ Place your order as early as possible to secure your production timeline.
DO NOT:
❌ Say "Make my doll look cute!" without reference photos or samples.
❌ Skip quality control discussions before production begins.
Want to learn more about manufacturing with Purnaa?
Check out our Stuffed Toy and Doll Catalog!
Get the full run down on our capabilities, expertise and product categories in our new catalog!
Get in Touch 💌
If you're interested in producing toys and dolls at Purnaa, get in touch with our team for a quote! To get started, follow this link.
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