How to Start an Activewear Brand with Private Label

# How to Start an Activewear Brand with Private Label Branding The first question we get from new brand founders isn't about fabric or colors. It's usually: "What is my true landed cost per unit, and how many pieces do I actually have to commit to before I know if this idea works?" That fear of getting stuck with 500 identical sports bras in your garage is rational. So let's address it head-on. We're Alpinario, a 20+ year sportswear factory in Zhejiang, China. We manufacture for other brands directly—no trading companies, no middlemen. Here is the exact, step-by-step process we walk every startup through when they want to start an activewear brand with private label branding. ## Positioning & line planning Before you message any factory, you need to define the product mix. Don't start with a logo. Start with a gap in the market. Are you targeting CrossFit athletes who need abrasion-resistant fabric, or yoga practitioners who prioritize four-way stretch? This decision dictates everything downstream: the fabric weight, the fit, the MOQ that makes sense, and the price point you can hit. **Your pre-brief checklist for your collection:** 1. **Define your hero product.** Pick one product that represents 60% of your initial sales projection. For us, that is often a high-waisted legging or a seamless sports bra. 2. **Choose your fabric specs.** Think in GSM (grams per square meter). For example, a standard training legging is usually 200–280 GSM. A lightweight running top is typically 120–150 GSM. If you don't know your GSM, ask us; we'll send you physical swatch cards within days. 3. **Set your price architecture.** If you want to retail at $60, your landed cost from a factory like ours is likely in the $12–$18 range depending on fabric, trims, and branding. This gives you a healthy margin for shipping, Ads, and returns. 4. **Decide on your SKU count for testing.** We advise against launching with 10 styles. Launch with 3 core styles. Get them right. ## Finding a manufacturer There are factories, and there are trading companies masquerading as factories. We are the former. When you visit a trading company, you see a showroom and a laptop. When you visit our floor, you see the cutting tables and the sewing lines. You want the latter. The most important factor in this step is verifying where the production actually happens and what the actual lead times are. Use the table below to benchmark what you should expect when comparing a direct factory versus a middleman: | Aspect | Direct Factory (Alpinario) | Trading Company | | :--- | :--- | :--- | | **MOQ** | 1 piece (1-pc custom available) | Often 100–300 pcs per color | | **Sample Time** | 3–7 days dispatch | 10–14 days (relaying) | | **Production** | 300 pcs done in 4–6 weeks after sample approval | 6–10 weeks (comm only) | | **Price** | Factory floor price (no markup) | Includes intermediary's 10–20% margin | | **Communication** | 24-hour reply from the production floor | 24-hour reply from a broker | We don't just take orders; we manage the entire production schedule. We handle the cuts, the sewing, the trims, and the QC. For your first order, you only need to commit to a low volume. You can test the market with a 50-piece batch if that is your strategy. Our standard is **no minimum order quantity**, which is rare in this industry. ## Sampling & fit sessions The sample is where your brand lives or dies. This is not the time to "just see how it goes." This is the time to be annoying with details. Once we receive your tech pack—or even just a reference photo of a design you like—our sample room takes over. We cut the pattern, source the fabric (Pantone colors are almost always available for polyester, and we also offer Nylon fabrics), and get the seed sample to you. Here is the sampling timeline you can expect: - **Day 1–2:** Brief received. Our team reviews the tech pack and confirms the fabric. You get a reply within 24 hours. - **Day 3–7:** Sample is cut and sewn. For simple designs, we dispatch the sample within 3-7 days. For more complex items with zippers or bonded seams, it may take slightly longer. - **Day 8–14:** You receive the sample (DHL/FedEx). Now, do the **fit session**. **Your Fit Session Checklist:** 1. **Wear-test it for 30 minutes.** Do squats, lunges, and a quick jog. Does the gusset stay in place? 2. **Check the shear factor.** Hold the fabric up to a strong light. If you can see your hand clearly through a legging, it's too thin for squat-proof coverage. 3. **Review the stitching.** Are the seams flat? Does the thread match the fabric color exactly? 4. **Wash it.** Wash the sample twice in cold water and hang dry. Does the elastic warp? Does the color fade? This is where cheap factories fail. If the sample isn't right, we adjust. It's that simple. We don't charge you a premium to re-cut a pattern; we just fix it. ## With Private Label Branding This is where we separate ourselves from blank apparel suppliers. You are not just buying clothes; you are building a brand. Private label branding means we attach your logo, your labels, and your story to the product. You don't need to own a factory or have a million units—you need quality control and accurate branding. Here is the full extent of "private label" services we offer on the floor: - **Logo Applications:** We offer heat transfers, embroidery (we have a specialized machine for sports logos), and screen printing. For performance wear, we often recommend silicone heat transfer because it doesn't lock in sweat like thick embroidery does. - **Labeling & Packaging:** We source and sew in your woven neck labels, satin care labels, and heat-transfer size dots. We also attach your custom hang tags and poly bags. We can even place the FBA barcode on the bag and ship directly to Amazon warehouses, saving you a round-trip of shipping costs. - **Design/ODM Support:** Don't have a tech pack yet? We have a library of proprietary fits and block patterns. You can pick one of our in-house designs and simply change the color and branding. We call this "semi-custom," and it drastically reduces development time. When we talk about modifying a design, we mean it. If you want a hidden phone pocket in the waistband, we will add it. If you want a specific internal drawstring in a men's short, we will source it. With a minimum order of just 1 piece, you have the flexibility to experiment with different branding placements without gambling your entire marketing budget on one product. ## Launch & first reorder So, you have approved the sample, and you are ready to launch. Your landing page is live, and you are running ads to a product that is currently in production. The worst thing you can do is oversell and miss your stock. Since we produce 300-piece mid-size orders in **4-6 weeks after sample confirmation**, you need to plan backward. **Your Launch Timeline Plan:** 1. **Week 1–2 (Pre-Sale):** Send your tech pack, approve the sample, and place the production order. 2. **Week 3–8 (Production):** While the factory sews, you run "pre-order" marketing. Collect emails, gauge interest, and secure credit card payments. 3. **Week 9 (Ship):** We ship (either ex-works, FOB, or DDP). For FBA, we put the labels on and send direct to Amazon. 4. **Week 10 (Launch):** Send the inventory to the fulfillment center. Launch. When the first batch drops, do not disappear into a new product line. Most of our successful clients reorder the exact same style within 3 months. Why? Because the AD spend has already been spent to acquire the customer; the margin is in the repeat sale. Once you have your first batch of sales data, look at your size curve. If you see that Medium and Large sell out instantly, but you have 30 Small leftover, don't panic. With our **1-piece MOQ**, you can order just the missing sizes in small quantities to top up. You don't have to eat a 200-piece minimum of Small just to restock a Medium. ## FAQ **How much capital to start?** You can start lean. With our no-MOQ structure, you can realistically start an activewear brand with **$1,000–$3,000**. This budget covers sample development, a small launch batch (for example, 50 pcs), basic trims, and shipping. We recommend saving at least $500 for professional product photography; it pays for itself. The biggest hidden cost is often not production—it's freight, so always get a DDP quote from us if you want the customs and logistics sorted out. **How many styles for launch?** Start with **2 to 3 styles**. Do not launch with a full collection of 15 pieces. For example, a 3-style capsule: "Leggings, Sports Bra, and T-Shirt" gives your catalog a sense of coherence while allowing you to test different fits. With our 1-piece MOQ, you can order 1 of each color to take listing photos, then place a small top-up order once sales start moving. **Domestic vs overseas factory?** If you are selling to the US/EU market, domestic (e.g., US-based) factories offer faster shipping (1-2 weeks) but at a higher Cost Per Unit (often 2-3x the FOB price). An overseas factory, like ours, takes longer in transit (usually 10-20 days to the West Coast) but allows you a better margin to actually pay for Facebook Ads and influencers. The trade-off is clear: you trade lead time for profit. If you are a startup, the profit matters more. We mitigate the lead-time risk with our 4-6 week production commitment and regular milestone photos during production. --- Ready to see your SKU on our cutting table? We respond to every brief within 24 hours, samples dispatch in 3-7 days, and with no minimum order, the risk is on us, not you. [Request a Quote](mailto:support@alpinario.com)