Manufacturing Capabilities: Inside the ZipaSports Factory in Sialkot
- 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
What ZipaSports is: one factory, not a trading office
ZipaSports is a manufacturer: the company owns and operates the production floor where the garments are printed, cut, sewn, decorated, inspected and packed. There is no stock catalogue: every order is made from the buyer's own artwork and size specification.
What "in-house manufacturing" means at ZipaSports
From approved artwork to closed carton, the work stays inside one building in Sialkot — with three exceptions, each made by a dedicated partner unit and set out in full below: silicone badges, knitted socks and woven labels. Fabric is bought in from mills, because ZipaSports is a cut-and-sew factory and not a textile mill.
| Item | Detail |
|---|---|
| Registered name | ZIPA SPORTS, trading as ZipaSports |
| Address | Talwara Mughlan, Sialkot, Punjab 51310, Pakistan |
| Established | 2005 |
| Staff | Around 162 |
| Capacity | 40,000–50,000+ pieces per month |
| Proprietor | Muhammad Saeed |
| Export sales | Umer — buyers deal with him on WhatsApp or email |
| Chamber membership | Sialkot Chamber of Commerce & Industry, A-71081 |
| Pakistan National Tax Number | 6808395-6 |
| Production model | Made to order only; no stock lines |
| Product families | Sports teamwear, combat wear, fitnesswear, dance teamwear, motowear, workwear, bags and accessories |
This page describes what the factory has. For an order walked through stage by stage, see manufacturing process.
Department by department: what each part of the factory does
The working areas below are listed in the order a garment passes through them.
| Department | What happens there | Equipment or method | What the buyer gets |
|---|---|---|---|
| Design studio | Artwork redrawn to production scale; colourways set against Pantone references | Artwork prepared and colour-matched in-house, not sent out | A free digital mockup within 24 hours, unlimited revisions |
| Pattern room | Patterns drafted for the chosen cut and graded across the size run | Computerised pattern making and size grading | Garments cut to your own size chart; the pattern is reused on repeats |
| Sublimation print room | Approved artwork printed to transfer paper at full panel width | Six 4-head sublimation printers | All-over prints, unlimited colours, nothing charged per colour |
| Heat press section | Printed dye gassed into the polyester under heat and pressure | Calender (roller) press for lengths; flatbed presses for cut panels | A print inside the fibre, not on top — nothing to crack or peel |
| Cutting room | Fabric laid, marked and cut to the graded patterns | Computer-controlled fabric cutting | Panels that repeat from first piece to last |
| Stitching lines | Panels assembled into finished garments | Flatlock, overlock, coverstitch and lockstitch lines | The seam matched to the garment, not one seam for everything |
| Embroidery | Crests, badges, sponsor marks and lettering stitched in thread | Tajima multi-head embroidery | One digitised file stitched identically on every piece |
| Screen print section | Spot-colour printing on solid-dyed garments | Flatbed screen printing, one screen per colour | Dense, opaque marks on cotton and fleece, which sublimation cannot print |
| DTF and DTG | Film transfers and direct-to-garment printing, short runs | DTF and DTG equipment | Full-colour decoration on dark and cotton garments, from 20–25 pieces |
| Embellishment bench | Rhinestone and crystal setting, puff print, heat transfer, tackle twill and appliqué | Rhinestone setting, heat presses, twill cutting and edge stitching | Dance, cheer and varsity finishes that cannot be printed flat |
| Bag manufacturing | Cutting and assembly of holdalls, backpacks and kit bags | Heavy-duty stitching for webbing, zips and reinforced bases | Bags made on the same site as the kit, shipped in one order |
| Quality control | In-line checks at the lines and a final inspection before packing | Measurement against the approved size spec; wash- and colour-fastness checks | Faults found on the line, not in your warehouse; photos on request |
| Labelling, packing and export desk | Neck labels, tags, polybags, cartons and shipping papers | In-house labelling and retail packing; export documentation | Retail-ready stock, invoice, packing list, certificate of origin |
Decoration methods available in-house, and what each is for
Nine decoration methods run inside the factory; which one suits depends on the fabric, the artwork and the quantity. The production manager proposes a method with your mockup.
| Method | How it works | Suited to | Fabric limits |
|---|---|---|---|
| Dye sublimation | Dye printed to paper, gassed under heat into the polyester fibre | All-over kit designs, gradients, player names and numbers | White or light polyester only; will not print on cotton or dark fabric |
| Flatbed screen printing | Ink pushed through a mesh screen, one screen per colour | Solid-colour tees, hoodies, repeat runs, few colours | Not for photographic artwork; each colour needs its own screen |
| Embroidery | Artwork digitised to a stitch file, sewn on Tajima multi-head machines | Crests, caps, polos, fleece, jackets, rank and sponsor marks | Small lettering loses definition, so a minimum letter height is agreed at artwork stage |
| DTF transfer | Printed to film, powdered, cured, then heat pressed on | Short runs, photographic logos, dark garments, cotton | Sits on the surface as a film; not used across a full garment panel |
| DTG (direct to garment) | Ink printed straight onto the made-up garment, then cured | Cotton tees and one-off samples with photographic detail | Cotton and high-cotton blends; not for polyester performance fabric |
| Puff print | A screen ink that expands under heat to stand proud of the fabric | Raised lettering on hoodies, tees and streetwear cuts | Bold shapes only; fine detail closes up as the ink rises |
| Heat transfer | Cut or printed vinyl pressed onto the finished garment | Names, squad numbers and sponsors added late in a run | Applied to flat panels; avoided over thick seams and ribbing |
| Rhinestone and crystal | Stones set to a template, then heat fixed | Dance and cheer costume, competition wear | Adds weight; kept off high-stretch zones so stones do not pop |
| Tackle twill and appliqué | Twill letters cut, laid on and stitched down at the edge | Baseball, american football, basketball and varsity jackets | Needs a stable base fabric; not used on light four-way stretch |
Names and numbers sit on a separate artwork layer, so a squad is personalised without redrawing the kit: names, numbers and sponsor logos.
Fabrics the factory works with, and the GSM ranges
Fabric is chosen per garment family, and every option below is one the factory cuts and sews regularly. GSM (grams per square metre) is quoted as a range: the honest way to compare weight between suppliers.
| Garment family | Fabric options | GSM range | Typical use |
|---|---|---|---|
| Jerseys and sublimated tops | 100% polyester interlock, mesh or pin-dot mesh, moisture-wicking finish | 140–180 GSM | Football, cricket, rugby, basketball, club kit |
| Polo and pit shirts | Polyester piqué or poly-cotton piqué | 160–200 GSM; poly-cotton 200–240 GSM | Club leisurewear, coaching staff, corporate |
| Shorts | Polyester interlock or microfibre; satin or twill for boxing | 140–180 GSM; satin 120–160 GSM | Match, training and fight shorts |
| Leggings, compression and bras | Nylon-spandex or polyester-spandex four-way stretch, squat-proof, 12–20% elastane | 240–300 GSM | Gym and studio ranges, base layers |
| Seamless knitwear | Nylon-elastane circular knit | 180–260 GSM | Seamless sets, ribbed gym ranges |
| Hoodies and joggers | Cotton-polyester fleece; performance poly fleece | 280–350 GSM; performance 240–300 GSM | Training tops, walk-out wear, streetwear |
| Rash guards | Polyester-spandex or nylon-spandex, flatlock seams | 180–220 GSM | BJJ, MMA, surf and swim training |
| Gi (BJJ, judo, karate) | Pearl weave or single weave; ripstop or twill trousers | 350–550 GSM jackets; 8–12 oz trousers | Competition and academy uniforms |
| Bags and cases | 600D polyester or 420D nylon, reinforced base and stitching | Denier rated | Kit bags, backpacks, holdalls, cases |
| Motocross | Ventilated polyester mesh jerseys; 600D pants, reinforced seat and knee | 150–180 GSM jerseys | MX and enduro kit, dealer ranges |
| Dance and cheer | Four-way stretch lycra and spandex, foil, velvet, mesh and sequin options | 180–220 GSM | Competition costume, studio uniform, cheer |
| Recycled options | GRS-certified recycled polyester on request | Matched to the equivalent virgin fabric | Brands with a recycled-content claim |
Sizes run adult XS–5XL, women's XS–4XL, plus youth and children's; the factory also cuts to a custom size chart you supply. Detail: fabrics.
Sewing, seams and pattern work
Four sewing systems run on the floor, and the seam is chosen for the garment rather than for whichever machine is free. Which seam went where is visible on the physical sample, so a buyer can check it before bulk starts.
| Seam or stitch | What it does | Where it is used |
|---|---|---|
| Flatlock | Butts two edges together and binds them flat, with no ridge against the skin | Rash guards, compression tops, leggings, base layers |
| Overlock | Trims and encloses a knit edge in one pass, and stretches with the fabric | Jerseys, shorts, general knit assembly, gussets |
| Coverstitch | Twin needles on top with a looper underneath: a flat hem that still stretches | Hems, cuffs, waistbands, neckline finishing |
| Lockstitch | Straight, firm, low-stretch seam | Woven shorts, gi jackets and trousers, bags, zips, pockets, labels |
Pattern work is computerised. A pattern is drafted for the cut you approve, graded across the size run and kept on file, so a repeat order is cut from the same pattern. Men's, women's and youth blocks are separate: a women's cut is drafted as a women's cut, not a small men's garment.
Supply your own size chart in centimetres or inches and the factory grades to it, then runs the final measurement check against that chart. Without one, the studio issues a chart with the mockup before any fabric is cut.
Capacity, minimums and how an order is scheduled
The factory runs from 20–25 pieces per design up to 40,000–50,000+ pieces per month on the same lines: a 25-piece club order is cut and sewn on the machines that run bulk.
| Stage | Time | Terms |
|---|---|---|
| Digital mockup | Within 24 hours | Free, unlimited revisions until you approve |
| Physical sample | 5–7 days | Charged at sample cost, credited against your bulk order |
| Bulk production | 15–25 business days after design approval | MOQ 20–25 pieces per design; lower on request; no MOQ limit for sportswear brands and companies |
| Express production | 7–12 days | At additional cost, subject to a free slot |
| Air courier | 5–10 days worldwide | DHL, FedEx or UPS |
| Sea freight | 3–6 weeks | For bulk where the delivery date allows |
A rush order is possible only when the inputs that normally hold production up are already settled.
| What a rush order needs | Why it matters |
|---|---|
| Print-ready artwork: vector, or high resolution with fonts outlined | Redrawing a low-resolution logo is the commonest delay in the studio |
| Confirmed colourway with Pantone references | Colour is matched to the reference at print, not guessed |
| An approved size chart | Nothing is graded or cut until sizes are fixed |
| A size breakdown by garment | The cutting room lays fabric to the breakdown; a late change means re-laying |
| Agreement to skip the physical sample | Sample plus courier adds 10–17 days; on express, approval is on the digital mockup |
The quality controls built into the floor
Inspection is a station on the line, not a final gate: garments are checked as they are sewn and again before packing, so faults are caught while the batch is on the floor.
| Control | Where it runs | Evidence a buyer can ask for |
|---|---|---|
| Print check against the approved mockup | Heat press section, first pressed panels of each run | Photographs of the first printed panels against the mockup, on request |
| Wash- and colour-fastness check on sublimated fabric | QC bench, on fabric from the production lot | Photographs of the washed swatch, on request |
| In-line stitching check | At the sewing lines, during assembly | A live video tour of the stitching lines while your order runs |
| Measurement check against the approved size specification | Final inspection, before packing | Measured pieces photographed against a tape, on request |
| Final inspection and packing check | Packing bench | Pre-shipment photographs of the packed order |
| Live process check | Anywhere on the floor, during office hours | A WhatsApp video tour of the print room and stitching lines |
The tolerances themselves — what passes, what fails and the ±1–1.5 cm measurement window — are set out on the quality control page.
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 claim route is on the quality guarantee page.
In-house versus partner units: the honest split
Three components are not made in this factory: silicone badges, knitted socks and woven labels are each produced by a dedicated partner unit, then applied to your order here. That is normal trade practice in Sialkot, because all three need knitting or moulding plant a cut-and-sew factory does not run.
| Process | Where it is done | Note |
|---|---|---|
| Pattern making, grading, cutting | In-house | Computerised; patterns stored for repeat orders |
| Sublimation printing and heat pressing | In-house | Six 4-head printers; calender and flatbed presses |
| Stitching and garment assembly | In-house | Flatlock, overlock, coverstitch and lockstitch lines |
| Embroidery | In-house | Tajima multi-head |
| Screen print, DTF, DTG, puff, heat transfer | In-house | All five decoration routes on site |
| Rhinestone setting and tackle twill | In-house | Embellishment bench |
| Bag manufacturing | In-house | 600D polyester and 420D nylon |
| QC, labelling, packing, export papers | In-house | Including certificate of origin and packing list |
| Silicone badges | Dedicated partner unit | Moulded to your artwork, applied here |
| Knitted socks | Dedicated partner unit | Knitted to your design; see socks and gloves |
| Woven labels | Dedicated partner unit | Woven to your artwork, sewn in on our lines |
| Fabric | Bought from mills and knitters | ZipaSports is a cut-and-sew factory, not a mill; incoming fabric is inspected for GSM, shade and faults |
Private-label finishing, packing and export documents
A garment can leave the factory carrying your brand and nothing else: no ZipaSports label goes into a private-label order. Labelling and packing are their own department, so retail-ready packing adds no separate lead time.
| Item | Options | Made where |
|---|---|---|
| Neck label | Woven to your artwork, or a printed heat-transfer label for tagless necks | Woven from a partner unit; printed labels and all sewing-in in-house |
| Size and care tags | Size, composition and wash-care tags in your layout | In-house |
| Hang tags | Card tags with your logo, barcode or QR code | Printed to your artwork; attached in-house |
| Polybags | Plain or printed with your logo | Packed in-house |
| Boxes and cartons | Branded retail boxes; master cartons marked with size and quantity | Packed and marked in-house |
| Retail-ready packing | Folded, tagged, polybagged and sorted by size | In-house |
| Export documents | Commercial invoice, packing list, certificate of origin | In-house export desk |
Artwork specifications: labels, tags and packaging. The brand-owner service: private label.
How to verify everything on this page
Do not take a capability list on trust — not this one either. Six checks confirm or disprove it before you place an order.
- Ask for a live video tour. On WhatsApp video, Monday to Saturday, 9:00 AM to 6:00 PM PKT, ask to be walked from the print room to the stitching lines to the packing bench.
- Check the chamber membership. ZipaSports is a member of the Sialkot Chamber of Commerce & Industry under A-71081.
- Check the tax registration. ZIPA SPORTS is registered in Pakistan under National Tax Number 6808395-6; ask for it to be shown on your quotation and on the commercial invoice.
- Request certificate copies. ISO 9001:2015, OEKO-TEX Standard 100 tested fabrics, BSCI audit, GRS recycled options, SGS testing and the Government of Pakistan export licence — certificate copies available on request. See certifications.
- Order a physical sample first. Five to seven days at sample cost, credited against your bulk order; a trading office cannot make your design in that window. See the sample policy.
- Ask a production question. Which seam goes on the hem? Which GSM is proposed, and why? A factory answers in one message.
Send artwork through contact, or read how to source custom sportswear from Pakistan first. Background: about ZipaSports.
Frequently Asked Questions
Does ZipaSports own its factory?
Yes. ZipaSports operates its own production floor in Talwara Mughlan, Sialkot, Punjab, Pakistan, established in 2005, with around 162 staff. Printing, cutting, stitching, embroidery, QC, labelling and packing are done by ZipaSports staff in that building, not subcontracted.
What machines does ZipaSports have?
In-house equipment includes six 4-head sublimation printers, calender and flatbed heat presses, Tajima multi-head embroidery, DTF and DTG, rhinestone setting, computer-controlled cutting, flatlock, overlock, coverstitch and lockstitch sewing lines, bag manufacturing, and labelling and packing stations.
How many pieces can ZipaSports make per month?
Capacity is 40,000–50,000+ pieces per month across all product families. The realistic figure for your order depends on the decoration method and the fabric, so confirm the schedule with Umer before fixing a delivery date.
Do you make everything in-house?
Almost. Silicone badges, knitted socks and woven labels are made by dedicated partner units and applied to your order here, and fabric is bought from mills. Everything else — pattern, print, cut, sew, decorate, inspect, label, pack — is in-house.
Can I see the factory?
Yes. A live WhatsApp video tour of the print room, stitching lines and packing bench can be arranged during office hours, Monday to Saturday, 9:00 AM to 6:00 PM PKT. Pre-shipment photographs of your order are also available.
Can you match a sample I already have?
Yes. Send the garment or clear photographs with measurements: the pattern room drafts to it, the studio matches colours to Pantone references, and fabric is matched by GSM and construction. A physical sample in 5–7 days confirms it.
What is the smallest order the factory will run?
20–25 pieces per design, with lower quantities possible on request. There is no MOQ limit for sportswear brands and companies, so an established brand can order any quantity up to the monthly capacity.
Do you do your own printing and embroidery?
Yes, both, on site. Sublimation, flatbed screen printing, DTF, DTG, puff print and heat transfer all run in-house, and embroidery is stitched on Tajima multi-head machines here. No decoration is sent out to a third-party print shop.
Does ZipaSports make its own fabric?
No. ZipaSports is a cut-and-sew factory, not a mill: fabric is bought from mills and knitters, then inspected for GSM, shade and faults on arrival. Be wary of any supplier claiming to weave, knit, print and sew on one site.
How quickly can the factory produce a rush order?
Express production runs 7–12 days at additional cost, against 15–25 business days for standard bulk, plus 5–10 days by courier. An express slot needs print-ready artwork, a confirmed colourway and an approved size chart.