How a 20+ Year Factory Handles Sourcing, Pricing & Reorders for D2C Brands

# Athleisure Apparel Supplier for D2C Brands: Workflow, Pricing & Reorder Strategy You’ve got a solid product idea, maybe a Shopify store ready to launch, and you’re comparing quotes from three factories. The landed cost for a 300-piece run of 280 GSM leggings looks reasonable at $8.20 per unit, but the sampling timeline is two weeks, and you can’t tell if they’re a trading company or a real mill. That uncertainty—the fear of a factory audit, the risk of a 6-week delay on reorders—is exactly what we solve at our own floor in Zhejiang. We’ve been manufacturing sportswear here for over 20 years, not as a trader, but as a full OEM/ODM/private label factory. This article walks you through our sourcing workflow, price breaks, and reorder planning so you can evaluate us as your athleisure apparel supplier for D2C brands. No fluff. ## Sourcing workflow Our sourcing process is designed to eliminate the back-and-forth that kills momentum for small brands. Here’s the exact sequence we follow when you reach out to us. **Step 1: Brief & Tech Pack (Day 1)** You send us your tech pack or just reference photos. If you don’t have a tech pack, we can create one from your design sketches. We respond within 24 hours. We’ll confirm the fabric composition (mostly polyester, can do nylon), GSM range (usually 180-320 for athleisure), and any custom details like logo placement, wash care labels, or FBA barcode requirements. **Step 2: Sampling (Day 2-8)** Once we agree on the spec, we prepare a sample. Our standard timeline is 3-7 days for sample dispatch. For a basic 300 piece order, sample approval happens within that window. We charge for the first sample, but if you place a production order, we deduct that cost. We use Pantone for color matching—almost any color is possible. We also do digital printing, screen printing, embroidery, and heat transfer for logos. **Step 3: Production Order (Day 8-35)** After sample approval, we move to production. For a 300-piece order, lead time is 4-6 weeks. That’s from sample sign-off to shipment. We track progress on our ERP system and share photos at key milestones: cutting, sewing, and packing. We do 100% visual inspection on every piece, not just spot checks. **Step 4: FBA Prep & Shipment (Day 35-38)** If you’re an Amazon seller, we can pre-apply FBA labels, poly bag each item, and ship directly to Amazon warehouses. No extra middleman. We’ve done this for hundreds of D2C brands. We also handle standard exports (FOB, CIF, EXW) depending on your preference. **Step 5: Post-Shipment Support** We store your pattern, fabric recipe, and Pantone codes. If you reorder in 6 months, the sample round is often skipped entirely because we have your exact spec on file. ## Price breaks Pricing for a private label athleisure line depends on quantity, fabric GSM, and complexity. Below is a representative price table for a standard 280 GSM polyester-spandex legging with a plain waistband, no pockets, one color, one logo. | Order Quantity | Unit Price (USD) | Lead Time (from sample approval) | |----------------|------------------|----------------------------------| | 1-50 pieces | $12.50 - $15.00 | 4-6 weeks (same as larger runs) | | 100-300 pieces | $8.00 - $9.50 | 4-5 weeks | | 500-1000 pieces| $6.50 - $7.50 | 3-4 weeks | | 2000+ pieces | $5.80 - $6.50 | 3-4 weeks | **Key observations:** - The biggest price drop happens between 50 and 300 pieces. That’s where we can amortize the setup cost for cutting and sewing. - 2000+ pieces gives you a roughly 10-15% discount over 1000 pieces, but the incremental savings are smaller than the step from 50 to 300. - For a 1-piece custom order (yes, we do MOQ 1), the price is higher because we still run the entire setup: pattern making, single-piece cutting, and sewing. This is useful for prototypes or sample selling. **What about fabric?** - 180 GSM (basic t-shirt weight): subtract about $1.00 per unit. - 320 GSM (thick, compression-grade): add about $1.50 per unit. - Nylon fabric: add about $2.00 per unit compared to polyester. We do not hide costs. We provide a full breakdown: fabric, labor, trims, packaging, and shipping. No surprises. ## Private label at supplier tier Many D2C brands start with a stock design and just add their logo. That’s fast, but it limits your margin. Our private label service means you own the product design, not just the label. We offer three tiers of private label for athleisure apparel: **Tier 1: Logo & Label Swaps** You choose a base design from our existing patterns (we have over 200 for leggings, tops, sports bras). We swap the label, wash care tag, and hang tag to your brand. MOQ: 1 piece. This is the fastest route—sample in 3 days, production in 4 weeks. Typical cost: $7.00 - $10.00 per unit for 300 pieces. **Tier 2: Modified Design** You take one of our patterns and modify it—change the waistband height, add a pocket, adjust the inseam length. We do the pattern grading and produce a new sample. MOQ: 50 pieces. Timeline: 5-7 days sample, 5-6 weeks production. Typical cost: $8.50 - $12.00 per unit. **Tier 3: Full Custom (From Scratch)** You provide a tech pack or a reference garment. We create a new pattern, produce a sample, and iterate until it’s right. We own the pattern after production, so reorders are seamless. MOQ: 100 pieces. Timeline: 7-10 days sample, 6-7 weeks production. Typical cost: $9.00 - $14.00 per unit. We do not use a single supplier for all trims. We manage the entire supply chain in-house: fabric from our partner mills, labels from our in-house printing shop, and packaging from our local supplier. This cuts lead time by about 2 weeks compared to using a trading company. ## Reorder planning The biggest mistake new D2C brands make is ordering too much inventory upfront, then scrambling for reorders when they sell out. We help you plan a reorder strategy that keeps your stock healthy without tying up cash. **Our recommended reorder cycle:** 1. **Initial order:** 300-500 pieces per SKU. This gives you enough inventory to test the market, run ads, and collect feedback. It’s small enough to avoid heavy storage costs, large enough to hit a decent price point. 2. **Buffer stock:** We recommend keeping 4-6 weeks of sales as safety stock. For a brand selling 100 units per week, that’s 400-600 units in reserve. 3. **Reorder trigger:** Place a reorder when your stock hits 8 weeks of supply. This accounts for our 4-6 week production lead time plus 2 weeks for shipping and customs. If you sell 100 units per week, reorder at 800 units. That way, you never run out. **How we handle reorders:** - We store your pattern, fabric spec, and Pantone codes. For a reorder, we often skip the sample round entirely. If it’s been more than 6 months, we may ask for a size set sample to verify fit, but that’s a one-week turnaround. - Reorder pricing is typically 5-10% lower than your initial order price because tooling and pattern costs are already covered. - For Amazon sellers, we can set up a recurring production schedule. Example: 200 units every 4 weeks, shipped directly to FBA warehouses. This smooths out your supply chain and avoids peak season delays. **Lead time comparison:** - Initial order (300 pcs): 4-6 weeks from sample approval. - Reorder without sample: 3-4 weeks from order confirmation. - Reorder with sample (if needed): 4-5 weeks. We’ve seen brands that reorder every 6 weeks for 18 months straight. Their production history with us means they skip the sample step entirely after the first order. That’s a 2-week saving every cycle. ## FAQ **What is the MOQ?** Our MOQ is 1 piece. You can order a single custom sample or a single unit for personal use. For production orders, we recommend at least 100 pieces to get the best price, but we will accept 50 pieces for modified designs and 100 pieces for full custom. There is no minimum order quantity for stock designs with logo swaps. **What is the sampling timeline?** We dispatch samples within 3-7 days from design approval. If you need a sample urgently, we can expedite to 3-4 days for an additional fee. The sample is sent via express courier (DHL, FedEx, UPS) and typically arrives in 3-5 business days depending on your location. For a small rush fee, we can do 2-day express. **Can you help with packaging and FBA prep?** Yes. We can poly bag, apply FBA labels, and ship directly to Amazon warehouses. We also provide custom hang tags, care labels, and neck labels. All packaging is included in our pricing if you specify it in the order. **How do I get a quote?** Email us at support@alpinario.com with your design, quantity, fabric preference, and any special requirements. We respond within 24 hours with a detailed quote including unit price, sample cost, and shipping estimate. --- [Request a Quote](mailto:support@alpinario.com)