Shedding is the #1 reason for product returns. Understanding the “Failure Points” in the factory allows brands to set better Quality Assurance (QA) standards.
The “Glue-Line” Failure
The most common cause of shedding is an insufficient Epoxy Plug. In the factory, the hair bundle is dipped in epoxy before being inserted into the ferrule.
The Defect: If the epoxy is too cold or too thick, it doesn’t “wick” up into the center of the hair bundle. This leaves the “inner hairs” unanchored.
The Solution: Brands should insist on Vacuum-Infused Gluing, which sucks the epoxy into every gap between the fibers.
The “Crimp” Stress
If the machine that “crimps” the ferrule to the handle is set too tight, it can actually “cut” the synthetic fibers at the base.
The Sign: If the brush is shedding short, broken hairs (rather than full-length ones), the crimping pressure is too high.
The Sign: If the whole bundle falls out, the epoxy-to-metal bond failed, usually due to oil residue on the inside of the ferrule.
Quality Control: The “Vibration Table”
Top-tier factories use a Vibration Table during the QA process. Finished brushes are placed on a vibrating surface for 60 seconds. Any “loose” hairs are shaken out at the factory so they never reach the consumer.