Wholesale Fitnesswear Manufacturer & Supplier — Bulk Custom Orders

What a wholesale fitnesswear order from our factory covers

Wholesale fitnesswear at ZipaSports is bulk cut-and-sew production of gym and studio apparel under your own label. Nothing is drawn from a stock rail: every carton is made to order against an approved mockup, in your colourway, with your woven neck label and your packing.

Six families run in the same building in Sialkot, Pakistan, which is why one purchase order can carry all of them: leggings and shorts, sports bras and seamless sets, gym tees, tanks and stringers, hoodies, joggers and jackets, compression and yoga wear, and gym bags.

The buyers placing these orders are distributors and wholesalers, teamwear resellers and kit suppliers, sports and lifestyle retailers, promotional-merchandise companies fulfilling a branded gym-kit contract, gym and studio groups kitting out staff and members, and established activewear brands moving production to a factory that will also hold their patterns. The full product map sits on the fitnesswear hub.

Minimum order quantity, and why there is no ceiling

The minimum order is 20–25 pieces per design, lower on request, and there is no MOQ limit for sportswear brands and companies. The floor exists so a buyer can test a shape before committing a season to it, not to cap what you can buy.

Two details decide how that floor lands on a real purchase order. Sizes are open inside a design, so 25 leggings can be split across XS to 3XL in whatever ratio your sell-through history supports. Whether a second colourway counts as a separate design depends on whether it changes the dye lot or the print file, and that is confirmed in writing with your quotation before you commit.

For a distributor planning a season buy, the useful number is not the minimum at all: it is the size curve per style per colour. Send that curve with your enquiry and the quotation comes back against your actual grid instead of a rounded estimate. MOQ explained covers how the grid is built if you are starting from nothing.

Bulk order planner: fabric, weight, minimum and decoration

Use this planner to size a wholesale order before you enquire. The weights shown are the option bands the factory runs; you fix the exact GSM and elastane percentage inside each band when the specification is signed off.

Bulk production is 15–25 business days after design approval on every line in the table, or 7–12 days on the express service at additional cost. A mixed order is quoted on one lead time: the sewing lines run in parallel and the order is packed once every family has cleared final QC.

Blank, blank-with-your-label or fully decorated

Wholesale buyers split into three habits, and the choice changes what arrives in the carton and where the decoration margin sits.

Blanks are the usual request from teamwear resellers who want to keep the decoration turnaround inside their own unit. Fully decorated is the usual request from retailers and promotional companies who need the carton to go straight onto a shelf or into a client's hands. You can mix the two on one order: for example, blanks in the core black legging and decorated pieces in the seasonal print. Label and packaging options are set out on labels, tags and packaging.

Repeat-order consistency between wholesale runs

The risk in a wholesale programme is never the first order; it is the second one arriving a shade off or half a centimetre short. ZipaSports controls that by keeping the approved record for each style: the graded pattern and size specification, the fabric and GSM, the Pantone references, the print file at production resolution and the approved photographs of the first shipment.

A reorder is quoted against that record rather than re-developed, so run two repeats run one. Two tolerances remain real and are worth writing into your own customer terms: a minor shade difference between dye lots, and a measurement tolerance of ±1–1.5 cm inside the size chart. Anything outside those is treated as a defect, not a tolerance.

Where a colour has to hold across seasons, ask for a Pantone match at specification stage and keep a sealed reference from the first run. Pantone colour matching for sportswear explains how closely a match can be held on polyester compared with cotton-blend fleece, which behaves differently in the dye house.

Mixed-category orders on one purchase order

Fitnesswear rarely ships alone. Because every category is cut and sewn in the same factory, a distributor can add sports teamwear, combat wear, workwear, bags and accessories or dance teamwear to the same order.

Each design still carries its own 20–25 piece minimum, so the order total is simply the sum of the designs. What you gain is one quotation, one production window, one shipment, one set of export documents and one freight cost instead of five. For a wholesaler serving gyms, clubs and corporate clients from the same warehouse, that is usually the single biggest saving on the order.

Mixed orders are also how most buyers test a new category cheaply: add 25 pieces of one gym bag or one hoodie to an existing teamwear buy, sell it through, and reorder at whatever quantity the sell-through justifies. The broader distributor workflow is on manufacturing for distributors.

Samples before you commit a wholesale run

Every wholesale enquiry starts with a free digital mockup returned within 24 hours, revised free of charge as many times as you need before approval. The mockup shows the garment in your colours with your logo placement, and it is what the production file is built from.

A physical sample follows in 5–7 days. It is charged at sample cost, and that cost is credited against your bulk order, so a buyer who samples three styles and then produces all three is not paying twice. Sampling is worth doing on any style you will hold in depth, because it is the only way to check hand-feel, opacity in a squat, waistband recovery and the true fit of your size chart against your customers.

Where you already have a garment you want matched, send it in and the pattern room measures and grades from that reference. Sampling terms are on sample policy, and the mockup process on free design mockup.

Sea freight, air freight and export documents

ZipaSports ships worldwide from Sialkot, and the routing choice is a straight trade between transit time and freight cost per piece.

Main export markets are the UK, USA, Canada, Australia, Germany and wider Europe, and the UAE and GCC. Export documentation is produced in-house with every shipment: commercial invoice, packing list and certificate of origin, plus pre-shipment photographs on request.

Import duty and any local taxes are the importer's responsibility and are not included in a factory quotation; import duties and shipping from Pakistan sets out what to expect in the main markets. Full terms are on shipping policy.

Quality Guarantee on every wholesale carton

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.

A manufacturing defect means a print fault such as a misprint, ghosting or a colour off the approved mockup beyond normal shade tolerance; a stitching fault such as an open seam, skipped stitches or loose or missing trims; a wrong size against the approved size specification; or the wrong garment or wrong quantity against the approved order. Minor shade variation between dye lots, a measurement inside the ±1–1.5 cm tolerance, a change of mind and sizing chosen wrongly by the buyer are not defects.

To claim, send photographs and your order reference on WhatsApp or by email within 7 days of delivery. We confirm within 24 hours in business hours, then remake the affected pieces free of charge and ship the replacements at no charge, or issue a credit if you prefer. Made-to-order garments carrying your own design and labels cannot be returned for change of mind. The written policy is on quality guarantee.