Gym Wear and Activewear Manufacturing in Sialkot, Pakistan
- Est. 2005 · Sialkot, Pakistan
- MOQ 20–25 pcs per design · no limit for brands
- Free 24h digital mockup
- Sample 5–7 days, credited on bulk
- Bulk 15–25 business days · express 7–12
- DHL/FedEx/UPS 5–10 days
- 🛡️ Free remake within 3 days
Where Sialkot sits in activewear manufacturing
Sialkot's activewear trade is a small-run, custom branch of Pakistan's much larger knitwear industry. The Punjab Government lists sportswear among the district's export product families, and Pakistan's sports-goods exports reached roughly 283 million US dollars in the July 2025 to February 2026 period, an increase on the same period a year earlier, according to Business Recorder.
The fabric side explains the position. Pakistan grows cotton and spins, knits and finishes it at scale, so a Sialkot factory buys cotton-polyester fleece, polyester interlock and piqué from Pakistan's own mill base, and sources polyester-spandex and nylon-spandex stretch knits for leggings and bras through the same supply chain. What Sialkot adds is the cut-and-sew, sublimation, embroidery and private-label finishing that turns that fabric into a 20-piece run of a brand's own legging rather than a 20,000-piece run of a retailer's basic.
What "made in Sialkot" means for gym wear: the legging, bra, hoodie or tee was cut and sewn in the Sialkot district of Punjab, Pakistan, from knit fabric sourced in the Punjab textile belt, usually in a factory that also prints, embroiders and packs it under the buyer's own label.
Disclosure: this page is published by ZipaSports, itself a Sialkot manufacturer.
Gym wear fabrics: composition, GSM and elastane by garment
Gym leggings and sports bras made in Sialkot are typically 240–300 GSM polyester-spandex or nylon-spandex with 12–20% elastane, and every other activewear garment has its own settled range. The table gives the options a buyer chooses between.
| Garment | Fabric composition options | Weight | Elastane and notes |
|---|---|---|---|
| Leggings, biker shorts, compression tights | Nylon-spandex or polyester-spandex, 4-way stretch | 240–300 GSM | 12–20% elastane; squat-proof at this weight; high-waist, scrunch and pocket variants |
| Sports bras and crop tops | Nylon-spandex or polyester-spandex, 4-way stretch | 240–300 GSM | 12–20% elastane; removable pads, racerback, longline and zip-front cuts |
| Seamless leggings, bras, sets | Nylon-elastane circular knit | 180–260 GSM | Ribbed and contour textures knitted in; sizing by stretch rather than cut |
| Gym tees, tanks, stringers | 100% polyester interlock, mesh or pin-dot mesh, moisture-wicking | 140–180 GSM | Sublimation-ready; cotton-rich options for screen print and DTF |
| Training polos | Polyester piqué or poly-cotton piqué | 160–200 GSM; 200–240 GSM | Embroidered logo |
| Hoodies, pump covers, sweatshirts | Cotton-polyester fleece | 280–350 GSM | Oversized, cropped and drop-shoulder cuts; brushed inside |
| Joggers and sweat shorts | Cotton-polyester fleece or performance polyester fleece | 280–350 GSM; poly fleece 240–300 GSM | Cuffed, straight-leg and cargo variants |
GRS-certified recycled polyester is available on request for the polyester-based pieces. The nylon-spandex, seamless knit and cotton-polyester fleece pages give the fabric detail.
Which decoration method suits which garment
The decoration method is decided by the fabric, not by preference: sublimation needs polyester, embroidery needs a stable base, and DTF and screen print sit on top of any fibre. The table shows the fit for each gym wear garment as it runs at a Sialkot factory.
| Garment | Sublimation | Screen print | Embroidery | DTF and heat transfer |
|---|---|---|---|---|
| Leggings and bras (polyester-spandex) | Good: all-over patterns, colour blocking, waistband logos printed in | Limited: ink cracks on high stretch | Small logos only; puckers on fine stretch knits | Good for a small logo on the hip or bra band |
| Seamless sets | No: pattern is knitted in, and nylon does not take sublimation dye | No | No | Small heat-transfer logo only |
| Polyester gym tees | Good: whole-garment designs and colourways | Good for one- or two-colour logos | Good for a chest crest | Good for multi-colour small runs |
| Cotton-rich tees | No: sublimation dye does not bond to cotton | Good | Good | Good |
| Fleece hoodies and joggers | No | Good, including puff print | Good: chest, sleeve and leg logos | Good for photographic or multi-colour artwork |
| Polos and track jackets | Track jackets in polyester: yes | Limited on piqué | Good: the standard for polos | Good |
A startup range usually mixes methods: sublimated leggings and bras, embroidered hoodies and joggers, and DTF or screen-printed tees. All of them run in-house at ZipaSports, alongside rhinestone setting for studio and dance crossover pieces. The sublimation vs DTF vs embroidery guide explains the durability differences.
A five-style first range for an activewear startup: quantities and timeline
A first activewear range of five styles at 20–25 pieces each comes to 100–125 garments and, adding the stages together, reaches the founder roughly eight to ten weeks after the brief when the sample is couriered for approval. The planner below is the shape most startup brands order from Sialkot.
| Style | Fabric and weight | Decoration | Minimum pieces | Sizes |
|---|---|---|---|---|
| High-waist legging | Polyester-spandex or nylon-spandex 240–300 GSM, 12–20% elastane | Sublimated all over (polyester-spandex) or small DTF logo (nylon-spandex) | 20–25 | Women's XS–4XL, mixed within the run |
| Sports bra | Matching polyester-spandex or nylon-spandex 240–300 GSM | Matching colourway; sublimated or small transfer logo | 20–25 | Women's XS–4XL |
| Oversized hoodie or pump cover | Cotton-polyester fleece 280–350 GSM | Embroidered chest logo; puff-print back | 20–25 | Unisex XS–5XL |
| Joggers | Cotton-polyester fleece 280–350 GSM | Embroidered leg logo | 20–25 | Unisex XS–5XL |
| Gym tee or tank | Polyester interlock 140–180 GSM or cotton-rich | Sublimation, screen print or DTF | 20–25 | Unisex XS–5XL |
The timeline runs as follows at ZipaSports. Day 1: free digital mockups for all five styles, with unlimited revisions. Days 2–10: physical samples in 5–7 days at sample cost, credited against the bulk order, then 5–10 days by courier if the founder wants them in hand. On approval: bulk production in 15–25 business days, with woven neck labels, printed size tags, hang tags and branded polybags applied in-house. Then 5–10 days by DHL, FedEx or UPS to the door. Once the brand is established there is no MOQ limit on reorders. The activewear brand guide covers pricing the range and launching it.
Pakistan vs China vs Bangladesh for activewear
China leads on the variety of technical and seamless knitting machinery, Bangladesh leads on very high-volume basics, and Sialkot in Pakistan leads on small custom runs with private-label finishing. A founder should place each style where it fits. All duty figures here are as of mid-2026; confirm the current rate with your customs broker before costing a range.
| Factor | Pakistan (Sialkot) | China | Bangladesh |
|---|---|---|---|
| Minimum order | 20–25 pieces per design at ZipaSports; no MOQ limit for established brands | Commonly 500–1,000+ pieces per style at contract manufacturers, according to Fabrioza | Large-line minimums; thousands per style is usual |
| Seamless and technical knits | Nylon-elastane circular knit at 180–260 GSM on a narrower range of gauges | Widest choice of seamless machinery, jacquards and engineered compression | Limited |
| Fleece and cotton basics | Good: local cotton and fleece mills; custom cuts at small runs | Good at volume | Strongest at very high volume and lowest unit cost |
| Sublimated pieces | Strong: in-house printing and cutting for all-over leggings, bras and tees | Strong | Weaker; basics-led |
| Private label at small runs | Woven labels, size tags, hang tags and polybags applied on 20-piece runs | Usually tied to larger minimums | Tied to large minimums |
| Duty into the UK and EU | 0% on apparel under UK DCTS, according to the TDAP DCTS note, and under EU GSP+, according to Business Recorder | Standard duty applies | Not covered by this page's sources; confirm with your broker |
| Duty into the USA | 19% after the August 2025 trade deal, reported by Dawn; included in ZipaSports' delivered price | Roughly 33% effective burden in 2026, according to MS Advisory | Not covered by this page's sources; confirm with your broker |
Sizing, fit and QC for stretch garments
Stretch garments are checked against the approved sample and a centimetre size chart, because a legging that measures correctly on the table can still fail on the body if the fabric weight or elastane content drifts. Four checks run on every activewear order at ZipaSports.
- Size specification. Women's XS–4XL, men's XS–5XL and youth sizes are available, or the brand supplies its own chart and cut. Measurements are checked against the approved spec with a tolerance of ±1–1.5 cm, which is the normal allowance in the size chart and not a defect.
- Opacity under stretch. Leggings are specified at 240–300 GSM because that is the weight at which the knit stays opaque under stretch, and the physical sample lets a buyer check the lightest colourway before bulk, since light colours show through first.
- Colour fastness. Sublimated fabric is wash-tested so that a black-and-neon colourway does not bleed, and dye lots are matched to the approved sample within normal shade tolerance.
- Seam and recovery. Flatlock and coverstitch seams on leggings and bras are checked for stretch and recovery so the waistband returns to shape after wear.
Pre-shipment photos are available on request, and a video tour of the cutting and sewing floor can be arranged in office hours, which run Monday to Saturday, 9:00 AM to 6:00 PM PKT.
Who orders gym wear from Sialkot, and where ZipaSports fits
Gym wear made in Sialkot goes to four buyer types: startup activewear and athleisure brands launching a first range under private label; gyms, CrossFit boxes and yoga or pilates studios ordering branded leggings, tees and hoodies for members and staff; distributors and wholesalers buying across a range; and corporate buyers ordering for company sports days. See startup fitnesswear brands, gyms and studios and wholesale fitnesswear.
ZipaSports manufactures all of it at its own factory in Sialkot, Pakistan, founded in 2005, with a production capacity of 40,000–50,000+ pieces per month spread across sportswear, fightwear and activewear. The fitnesswear range covers leggings and shorts, gym tops, sports bras and seamless and hoodies and jackets; typical first-range pieces are scrunch-bum leggings, seamless sets and oversized drop-shoulder hoodies.
There is no stock catalogue: every piece is made from the brand's own design, with a free digital mockup within 24 hours, a sample in 5–7 days at sample cost credited against bulk, 20–25 pieces per design to start and no MOQ limit once the brand is established. Quality Guarantee: if any garment arrives with a manufacturing defect, we remake it free of charge — the remake goes into production within 3 days of your report. The Startup Launch Programme packages these terms for new brands, and the Made in Sialkot hub covers the wider cluster.
Frequently Asked Questions
Is Pakistan good for activewear manufacturing?
Yes, Pakistan is good for activewear in small custom runs, because Sialkot factories cut, sew, sublimate and private-label leggings, bras, hoodies and tees from 20–25 pieces per design using knit and fleece fabric from Pakistan's mills. China remains stronger for seamless machinery variety and Bangladesh for very high-volume basics.
Can I launch an activewear brand with 20 pieces per design?
Yes, ZipaSports takes 20–25 pieces per design for a first activewear range, with lower quantities possible on request and no MOQ limit once the brand is established. A five-style range of leggings, bra, hoodie, joggers and tee comes to 100–125 pieces, all under the brand's own labels.
What GSM should gym leggings be?
Gym leggings are typically 240–300 GSM in nylon-spandex or polyester-spandex 4-way stretch with 12–20% elastane, which is the weight at which a legging stays squat-proof. Seamless leggings run lighter at 180–260 GSM because the circular knit is denser by construction.
Does Sialkot make seamless gym wear?
Yes, seamless leggings, bras, vests and sets in nylon-elastane circular knit at 180–260 GSM are available from ZipaSports in Sialkot, on a narrower range of machine gauges than a Chinese seamless specialist offers. Patterns and ribs are knitted in, and logos are added by small heat transfer.
Is Pakistan or China better for manufacturing leggings?
Pakistan is better for a custom legging in runs of 20 to a few hundred pieces with private-label finishing and 0% duty into the UK and EU as of mid-2026; China is better for engineered seamless or technical compression in thousands of units, where contract manufacturers commonly want 500–1,000+ pieces per style, according to Fabrioza's Pakistan-versus-China comparison. Confirm current duty rates with your customs broker.
How long does a first activewear range take from Sialkot?
Adding the stages together, a first range reaches the founder roughly eight to ten weeks after the brief: a digital mockup within 24 hours, samples in 5–7 days plus courier time, then bulk in 15–25 business days after approval and 5–10 days by DHL, FedEx or UPS.
Can my own labels and packaging be used on gym wear made in Pakistan?
Yes, woven neck labels, printed size tags, hang tags and branded polybags or boxes are applied in-house at ZipaSports on runs as small as 20–25 pieces per design, so the garment leaves the Sialkot factory as the brand's own product. Woven labels are made by a dedicated partner unit.
Which printing method works on leggings?
Sublimation is the method for leggings in polyester-spandex, because it dyes the design into the fibre and stretches with it, while screen-print ink cracks on high stretch. Small hip or waistband logos can also be applied by DTF or heat transfer. Nylon-spandex takes only the small transfer, not sublimation.
Are recycled fabrics available for gym wear made in Sialkot?
Yes, GRS-certified recycled polyester is available on request for polyester-based gym wear such as sublimated leggings, bras, tees and performance fleece. Certificate copies are available on request, and the recycled option is quoted per order alongside the standard fabric.
Do I pay import duty on activewear from Pakistan in the UK?
Activewear made in Pakistan enters the UK free of import duty under DCTS Enhanced Preferences, as of mid-2026, with VAT charged at import. The EU applies 0% under GSP+; the USA charges 19%, reported by Dawn, which ZipaSports includes in its delivered price so a US buyer pays nothing extra at customs. Confirm current rates with your customs broker.