Flag bunting for cafés during the World Cup and European Championship
For promotional campaigns around the World Cup and the European Championship, Devos Arrotex produced a total of 30,000 flag bunting lines for AB InBev. The bunting was used as promotional material in cafés throughout Belgium and had to be identical, durable and visually uniform across the entire production run.
Each bunting line consisted of 18 flags, representing 9 different countries. The order of the countries was fixed and had to be repeated exactly twice on every line (2 × 9). With this production volume, a controlled and reproducible manufacturing process was essential to avoid any mistakes in sequence or positioning.
Material preparation and tape processing
For this project we were responsible for supplying and preparing the red tape ourselves. The base material was cut internally to a width of 20 mm and then used to assemble the bunting lines.
The tape was folded around the top of the flags and stitched through, creating a clean, closed finish with sufficient strength for use in hospitality environments.
Key steps in the process:
- Supplying and cutting the red tape to 20 mm
- Positioning the flags according to a fixed sequence
- Continuous stitching with consistent stitch spacing
Controlled production at large volume
To consistently respect the fixed sequence of the 9 countries, we developed a specific program for our sewing machines. Thanks to this semi-automatic setup we were able to:
- technically guarantee the correct flag sequence
- ensure consistent stitching quality
- achieve high repeatability across 30,000 pieces
This approach combined production speed with process control, which was essential to meet the required timeline.
Finishing and packaging
After assembly, all bunting lines were individually packed in zip bags, ready for distribution to the cafés. Packaging was also integrated into our production workflow.
This project illustrates how we manage material sourcing, cutting, textile assembly and final packaging within a single production flow. The focus was on precision, reliability and repeatability within an industrial context involving large volumes and fixed configurations.
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