Scaling From 50 Pieces to 1,000: What Changes at Each Step

The right way to produce 50 garments and the right way to produce 1,000 are different in almost every respect. Growth in apparel is a series of threshold changes rather than a smooth curve, and knowing where the thresholds are prevents both over-engineering a small order and under-preparing a large one.

20 to 49: the testing stage

• **DTF or DTG for decoration.** No setup cost, full colour available, and screen printing cannot compete at this volume.
• **Stock garment colours.** A bespoke dye lot is impossible at this quantity and unnecessary.
• **No formal sampling.** The run is the sample. Wash one, wear one, sell the rest.
• **Spread sizes deliberately** to learn your curve rather than to maximise revenue.

The purpose of this stage is information, not margin. Base pricing applies, and what you are buying is the answer to whether anyone wants this.

50 to 249: the crossover

Screen printing starts to overtake digital methods on cost for simple designs — around 50 pieces for a single colour — and brings better hand feel and durability. This is where paying for proper artwork begins to pay back.

Roughly 11% off at 100 and 20% at 250 in our tiers. Reorder the sizes that sold rather than repeating the original spread, and start holding a small buffer if you are selling continuously.

250 to 999: specification becomes worth it

1. 1**Custom colours become viable,** since the order consumes a meaningful share of a dye lot and lab dips are worth the cycles.
2. 2**Woven labels and custom trims** reach their own minimums economically.
3. 3**Pre-production sampling matters,** because being wrong is now expensive enough to justify the extra cycle.
4. 4**Tolerances should be agreed in writing,** since a defect rate on 500 pieces is a real quantity.
5. 5**28% to 35% off** in our tiers, which is where the discount curve starts to flatten.

1,000 and above: it is a supply chain

At this volume you are managing production rather than placing orders. Fabric is bought for you rather than drawn from stock, lead times lengthen because the run is larger, and freight moves from parcel to pallet or container.

Up to 35% off at the deepest tier, and the setup component of the unit price has effectively disappeared. What you are paying for is fabric, labour and decoration.

What has to change about you

Cash, mostly. Each step multiplies the money committed before any of it returns. Brands fail at this transition more often than at any other, because the order that made commercial sense on a spreadsheet consumed the working capital needed to keep operating.

The discipline that works is to move up one tier at a time, on evidence of sell-through, rather than jumping to the tier with the best unit price. The unit price is not the constraint; the cash and the sell-through are.