In the fast-growing beauty market, speed and reliability mean everything. One of our Nigerian wholesale customers came to APOGROUP with an urgent request: 5,000kg of 100% human hair extensions needed within 30 days.
For many suppliers, this sounded impossible. But for us, as the leading Vietnamese hair factory with 15+ years of experience, it was a challenge worth taking.
The Challenge: A Massive Order on a Tight Deadline
The challenges were clear from the start. 5,000kg meant thousands of bundles, and every single one needed to meet strict standards. The tight deadline added extra pressure, leaving no room for errors or delays. On top of that, the customer required absolute consistency in quality. Whether it was the first kilogram or the last, everything had to look and feel the same. Handling volume is one thing, but maintaining quality across such a scale is where true capability is tested.
The APOGROUP Approach: How We Made It Happen
From the very beginning, APOGROUP was built with an efficient system that allows us to respond quickly and confidently, especially when customers place large-scale orders. With a 34,000m² factory and over 700 skilled workers, we quickly increased production capacity.
Our production goal is simple: keep the line balanced so every stage flows without bottlenecks. On average, APOGROUP produces 160–200 kg of finished hair extensions per day, equivalent to around 1,600–2,000 bundles (each bundle ~100 grams).
We operate on a two-shift system (8 hours each), with specialized teams responsible for each production stage. The daily quota is divided across these teams, so everyone knows exactly what needs to be achieved to keep the line moving.
Step 1: Raw Hair Sorting
The process begins with sorting raw hair by length, texture, and color tone. This ensures every bundle starts with consistent material.
- Daily capacity: ~400–450 kg of raw hair/day (2 shifts)
- Team size: 20–25 workers
- QC checkpoint #1: Inspect for lice, chemical residue, mixed directions, length grading, and impurities.
This stage ensures only clean, usable hair moves forward — reducing waste later.
Step 2: Washing & Drying
Sorted hair is washed and sanitized, using industrial machines with low-pH shampoo to keep the cuticle intact. Then we will dry them in controlled environments to prevent over-drying.
- Capacity: ~350–380 kg/day
- Cycle: 3–4 hours washing + 6–8 hours drying
- QC checkpoint #2: Smell test, moisture measurement, and tensile strength pull, tangle test.
Step 3: Alignment & Hackling
Here, workers carefully align strands so cuticles run in the same direction. This is the most labor-intensive stage and a key to quality wefts.
- Daily output: ~200 kg/day net after alignment (≈ 2,000 bundles)
- Team size: 40–50 workers/shift
- QC checkpoint #3: Shedding test, alignment check, and weight accuracy.
Step 4: Weft Sewing
Here, hair becomes a finished product
- Wefting lines: 20 machines × 2 shifts × 120 bundles/machine/shift
- Capacity: ~4,800 bundles/day = 480 kg/day
- QC checkpoint #4: Stitch strength test, bundle weight, visual finish inspection.
By balancing machine and manual work, we hit the daily quota while tailoring products to specific customer needs.
Step 5: Coloring & Toning
Not all hair stays natural black — the orders require some shades and textures.
- Capacity: 200–250 kg/day
- QC checkpoint #5: Shade matching under lightbox, rinse test, and flat-iron heat test.
Step 6: Finishing & Conditioning
Before packaging, bundles are conditioned with nourishing spray, checked for shine and smoothness, and dried to the final spec.
- Capacity: ~220–240 kg/day
- QC Check #6: Elasticity test, comb-through check, dryness % check.
Step 7: Final Inspection & Packaging
Every bundle goes through inspection—a strict international sampling method. Bundles are then packed in moisture-proof bags with desiccants.
- Capacity: ~200 kg/day final pass
- QC Check #7: weight, appearance, length verification, re-inspection of shade/texture, and shedding/tangle test.
Logistics is also a key piece. At the same time of production, we partnered with trusted international shipping companies to guarantee that once the order was ready, shipping would be fast, secure, and on schedule.
The Outcome: Delivery and Customer Success
After 30 days of intense focus, coordination, and teamwork, the entire 5,000kg order was completed and shipped on time, exactly as promised. The customer was not only satisfied with the quality of the hair but also impressed with how we managed such a large and urgent request. The success of this order didn’t just end at delivery; it opened the door for long-term cooperation. Today, that Nigerian customer continues to place big orders with us, confident that APOGROUP will always deliver both quality and reliability.
Why This Story Matters
This story is more than just about numbers. It’s proof that APOGROUP has the ability, the system, and the people to handle big, urgent orders without compromising quality.
- Capability at scale – With a modern factory, skilled workers, and an effective production line, APOGROUP can handle urgent, high-volume orders for customers in Nigeria, the USA, Europe, and other global markets. Whether it’s 50kg or 5,000kg, we can do it!
- Consistency in quality – Many suppliers struggle to keep every batch the same when the volume is huge. At APOGROUP, our strict quality control ensures that every bundle, from the first to the last, meets the same premium standard.
- Trust and reliability – When a customer places a massive order, they’re not just buying hair, they’re putting their reputation in our hands. This success story proves that APOGROUP is a partner who delivers on promises.
No matter how big your vision is, APOGROUP is here to make it happen!
