For sourcing teams that need spec on paper and spec on goods

Custom Activewear Manufacturer — OEM, ODM and Private Label

Q: How is MOQ split across sizes? Does 100 mean 100 per SKU or 100 × 5 sizes?

Our MOQ 100 is the total piece count for one SKU — not per size. You decide the size curve. If your sales data says XS=10% / S=20% / M=30% / L=25% / XL=15%, we cut 10/20/30/25/15 pieces. Most factories quote 100 per size, which means 500 pieces minimum once your size curve splits. We don't.

Q: What's your sampling cost and turnaround time?

USD 45 per sample. 5 working days on fabric we have in stock; 12 working days if your fabric is custom or sourced. You get a full one-piece sample with pattern, fabric swatch, and lab dip color match. No bulk commitment required.

Q: I don't have a tech-pack — can I still work with you?

Yes. Our 16 pattern-makers can build a tech-pack from a reference sample or a sketch. The pattern fee is USD 220 and it takes 7-14 days. After that we proceed exactly the same way as a client who brought their own tech-pack.

Q: What does AQL 2.5 actually mean for my order?

AQL stands for Acceptable Quality Limit — the inspection sampling rate per ANSI/ASQ Z1.4. In plain English: we randomly inspect a statistically valid sample of pieces from your batch (typically 80-200 pieces depending on PO size) and check for defects. AQL 2.5 is the standard quality level retailers like Target and Costco require. We share the inspection report with every shipment.

Q: What's your on-time delivery rate? Can I see evidence?

12-month rolling OTD is 92.4%. We log every shipment with promised date, actual date, and delay reason. The full log is reviewable under NDA for active buyers. We also send monthly OTD reports to repeat clients without being asked.

Q: Difference between OEM, ODM, and Private Label?

OEM: you bring the tech-pack and the design — we cut and sew to your spec. ODM: you pick from our pattern library and customize color, fabric or logo — we skip the pattern-making cycle so you launch faster. Private Label: add your hangtag, care label, polybag and master carton on top of OEM or ODM. Private Label has no extra MOQ — it's an add-on.

Q: Payment terms and FOB/CIF options?

Standard PO terms: 30% deposit on PO confirmation, 70% balance on BL (bill of lading) copy. FOB is default (you arrange shipping from our nearest port). CIF available on request (we arrange shipping to your destination port). For active buyers with repeat orders, we offer NET-30 on the balance.

Q: How do you handle batch-to-batch color consistency?

Every PO starts with a lab dip — your approved color sample. We measure ΔE (color delta) against the lab dip using a spectrophotometer at three checkpoints: fabric receiving, mid-production, and pre-shipment. ΔE must stay ≤ 1.5. The lab dip is stored in your client master file and pulled for every reorder — so a reorder 6 months later matches the original.

OEM cut-and-sew, ODM, private label and team-set sublimation — MOQ 100 total piece count split flexibly across XS-XXL, sampling at USD 45 in 5 working days, ΔE ≤1.5 batch-to-batch on every PO. Full service lineup →

Send your tech-pack Request capability deck (PDF)

Replies within 1 business day · NDA on request · Sample fee USD 45, 5 working days

12Production Lines

280+Staff Onsite

8+Years / Since 2017

5Certifications On File

5-second scorecard

Custom Activewear Manufacturer Tolerances

Six numbers your last factory wouldn't put on a webpage.

Spectrophotometer reading delta E 1.3 next to fabric swatch and lab dip

QC inspector measuring garment POM points with measuring tape

±5%

GSM tolerance

Per-batch fabric weight tolerance vs spec. Lab report attached to every PO.

ΔE ≤1.5

Spectrophotometer color delta

vs your approved lab dip. Black-on-black, neon, marl — same rule.

±0.5 cm

Garment measurement

Tolerance on POM points: chest, waist, inseam, sleeve.

MOQ 100

Total piece count / SKU

Not per size. Split XS-XXL however your size curve reads.

AQL 2.5

Pre-shipment inspection

Measurement, defect photos and packing records prepared per PO.

92.4%

12-month rolling OTD

Schedule log + delay notes reviewable under NDA for active buyers.

Spec on paper. Spec on goods. Audit any PO.

Every shipment includes a per-batch AQL 2.5 report and a spectrophotometer ΔE log. Pull them at any stage.

Product breadth

Custom Activewear Product Families

Six families running side-by-side on the same floor.

Black performance leggings with cross-grain stretch texture

Training & Performance

High-stretch performance pieces — anti-pilling, moisture-wicking, four-way stretch builds for studio and gym SKUs.

leggingssports brasjoggersshortscompression top

View Family →

Grey oversized hoodie flat-lay on neutral background

Athleisure / Lifestyle Fit

Heavier-weight knits and looser fits for off-gym wear and lounge collections.

teehoodiejacketpulloversweatpant

View Family →

Red and blue sublimated jersey with back number 12

Team & Club Apparel

Sublimated team sets with number, name, crest personalization built into the pattern — driven by your roster CSV.

jerseytraining teewarm-upcustom team set

View Family →

Fitness Wear

Studio-to-floor training pieces — breathable seamless sets and supportive tops built for high-rep strength and conditioning sessions.

tankfitness toptraining shortseamless setworkout legging

View Family →

Yellow windbreaker on outdoor trail backdrop

Outdoor / Running

Wind-blocking shells, lightweight running tights, technical singlets for trail and road brands.

windbreakerrunning tightssinglettechnical shell

View Family →

Headband, arm sleeve, socks and cap matching combo flat-lay

Accessories

Cut-and-sew accessories matched to your main collection's fabric and dye lot.

headbandarm sleevesockscap

View Family →

Activewear we manufacture by sport & discipline

Custom yoga activewear and leggings manufacturing

Yoga ApparelSquat-proof yoga & studio activewear

Custom gym training sportswear manufacturing

Gym ClothingAbrasion-tested gym training wear

Custom cycling jersey and race kit manufacturing

Cycling ApparelAero race-fit cycling kit

Custom soccer team jersey and kit manufacturing

Soccer ApparelSublimated soccer team kits

Custom basketball team uniform manufacturing

Basketball ApparelReversible basketball uniforms

Custom athletic streetwear manufacturing

Custom StreetwearHeavyweight athletic streetwear Swimming ApparelChlorine-resistant swimwear & team suits Golf ApparelMoisture-wicking polos & performance layers Fishing ApparelUPF sun-protection shirts & vented shorts Equestrian ApparelStretch riding tights & show shirts Tennis ApparelQuick-dry court dresses, polos & skorts Hockey ApparelSublimated field & ice hockey kits

Top activewear SKUs by product category

Custom yoga pants and leggings manufacturer

Yoga Pants & LeggingsSquat-proof performance leggings

Sports BrasLow-to-high-impact activewear support

Custom compression sportswear manufacturer

Compression WearGraduated compression sportswear

Custom men's athletic hoodie manufacturer

Men's HoodiesHeavyweight men's athletic hoodies

Service tracks

OEM, ODM & Private Label Manufacturing Services

Eight service tracks for repeat clients.

OEM (Cut-and-Sew)

You send tech-pack and approved lab dip; we cut-and-sew to spec.

MOQ 100/SKU total piece
Lead 35-42 days (fabric-on-stock)

See service spec →

ODM

Pick from our pattern library, swap color, fabric or logo, skip the pattern-making cycle.

MOQ 100/SKU
Lead 30-40 days

See service spec →

Private Label

Your hangtag, care label, polybag and master carton — full label kit assembled by us.

Add-on to OEM/ODM
No extra MOQ

See service spec →

Small-Batch Sampling

One piece per sample. Sample fee USD 45. Fabric-on-stock turn in 5 working days.

1 piece per sample
5 working days

See service spec →

Custom Print & Embroidery

Sublimation, DTG, silicone, 3D embossed, flat embroidery, heat transfer — all in-house.

Combinable on same PO
No separate MOQ

See service spec →

Team Customization

Per-piece number, name, crest, sponsor block driven by your roster CSV.

MOQ 100 pieces
Lead 18-25 days

See service spec →

Tech-Pack & Pattern

No tech-pack yet? Our 16 pattern-makers build one from a reference sample or your sketch.

Pattern fee USD 220
7-14 days

See service spec →

White Label

Rebrand our ready-made activewear designs under your own name — no tech-pack, no tooling, fast to launch.

Ready-made designs
Your brand, no tooling

See service spec →

Production line wide view with multiple service stations running in parallel

Factory at a glance

Activewear Factory Capacity Datasheet

Copy these rows into your supplier scorecard.

Metric

Value

Monthly capacity

380,000 pieces (rolling 12-month average)

Single-PO capacity range

50,000 – 100,000 pieces

Production lines

12 (4 sublimation · 5 cut-and-sew · 3 team-set)

Line allocation

Reserved by approved sample, fabric arrival, shipment date

Staff on site

280 (32 QC · 16 PM · 8 lab · 224 sewing/finishing)

Factory footprint

8,500 m² (single-site, no offsite subcontracting)

Bulk lead time (OEM)

35-42 days fabric-on-stock · 48-58 days fabric-to-order

Sample lead time

5 working days fabric-on-stock · 12 working days fabric-to-order

On-time delivery

12-month rolling 92.4% (NDA-reviewable logs)

QC pass rate

Pre-shipment AQL 2.5, 12-month avg 98.5%

Years on the floor

8 (since 2017)

Want this as a one-page PDF? Section below ↓

Factory overhead view showing production lines, cut-and-sew stations and packing area

Cutting room cross-section with lay marker on long table and operator

QC inspector station with measuring tools and lab dip cards

Want the production numbers before sales calls?

One-page PDF capacity datasheet — direct download, no email gate. Forward it to your sourcing director or operations lead.

Download capacity datasheet (PDF)

No form. Direct PDF, 280 KB. Updated quarterly.

Problems → solutions

Common Activewear Manufacturing Problems Solved

Six problems sourcing directors keep flagging — and how our setup answers each.

Problem

Industry standard

Berun

Tolerance enforcement

Tolerance numbers live inside the MSA, not on the website. You see them after you've already signed.

±5% GSM, ΔE ≤1.5, ±0.5 cm — printed on this page, written into every PO, attached as report per shipment.

MOQ math

MOQ 100 / SKU often reads as 100 × 5 sizes = 500 unit minimum once your size curve splits.

MOQ 100 is the total piece count. Split XS-XXL however your size curve actually sells. Real number for a 5 SKU pilot: 500 total, not 2,500.

Sampling start

Sample fee plus a 5-10 piece minimum to even open a sample order.

One piece per sample. USD 45 fee. 5 working days on fabric-on-stock styles. No bulk commitment required.

On-time delivery accountability

OTD% lives in the contract; you find out it slipped after the second late PO.

12-month rolling OTD 92.4%. Shipment schedule logs, packing records and delay notes reviewable under NDA for active buyers.

Single-site vs subcontracted production

"Factory" often subcontracts 40-60% of PO to third-party workshops with no QC alignment — you find out from inconsistent batches.

Single 8,500 m² site, 280 staff in-house. No offsite subcontracting. All 12 production lines under one roof, one QC team.

Batch-to-batch color consistency

Reorder 6 months later, ΔE drift averages 2.5-3.0 — color visibly doesn't match.

Spectrophotometer ΔE ≤1.5 enforced batch-to-batch. Lab dip approved once, locked into PO master file, audited every reorder.

From inquiry to delivery

Activewear Sourcing Process: Tech-Pack to Bulk

From first email to delivered cartons — five steps over 50 to 58 days.

Tech-pack document and RFQ printout next to a reference garment on desk

Step 1 · Inquiry

Day 0-3

You send: spec / tech-pack OR reference sample (no tech-pack? we build one)
Berun returns: RFQ with MOQ, lead time, sample fee quote, suggested fabric options
Price: free (no obligation)

Pattern-maker at table cutting sample with lab dip color card visible

Step 2 · Sample

Day 4-9 stock · 4-16 to-order

You send: USD 45 sample fee + lab dip color spec
Berun returns: 1-piece sample + pattern + fabric swatch + ΔE ≤1.5 lab dip match
Price: USD 45 sample fee

Approved sample with paper sign-off form and PO confirmation document

Step 3 · Approval

Day 10-13

You sign off: pattern + fit + fabric + color
Berun returns: locked tech-pack + PO confirmation + 30% deposit invoice
Price: 30% deposit on PO total

Production line running full with WIP garments at multiple stations

Step 4 · Bulk Production

Day 14-49 (OEM 35-42 days)

You receive: WIP photos at cutting / mid-production / pre-shipment
Berun runs: cut → sew → print/embroidery → AQL 2.5 pre-shipment QC
Price: balance reminder at AQL pass

Packed cartons stacked with shipping label and container in background

Step 5 · Delivery

Day 50-58

You receive: pre-shipment QC report + packing photos + shipment ID
Berun ships: FOB or CIF per PO + 70% balance due on BL copy
Price: 70% balance on BL

Compliance on file

Activewear Manufacturer Certifications

Five certifications on file — request the PDFs by name.

$OEKO-TEX Standard 100 certificate$ OEKO-TEX

BSCI

WRAP Gold

GRS

Higg FEM

OEKO-TEX Standard 100

Fabric tested for harmful substances per Annex 6, covering our knit and woven main fabrics.

23.HCN.74521Request PDF →

BSCI

Social compliance audit, Class B+ rating in the August 2024 renewal. Covers our main facility and dormitory.

BSCI-CN-2024-08-15Request PDF →

WRAP Gold

Worldwide Responsible Accredited Production at Gold tier — the highest of three tiers.

WRAP-GLD-156823Request PDF →

GRS

Global Recycled Standard for our recycled-polyester product line — rPET jerseys, leggings, training tops.

CU 1014387 GRS-2024Request PDF →

Higg FEM

Higg Facility Environmental Module, score 82/100 in the 2024 SLCP-verified assessment.

HIG-FEM-2024-CN-08Request PDF →

Get all five as a zipped pack →

Real POs

Custom Activewear Manufacturer Case Studies

Different ICPs, different PO sizes, different first-orders — same line allocation, same QC team, same lab dip lane.

4-color performance leggings stack on light background

ICP-A · Sourcing Director

Boulder, CO · $18M ARR Athleisure Brand

4,200-piece first PO · 4 colors

Performance leggings + sports bras. Lab dip approved first round; bulk delivered 17 days OTD; reorder triggered 6 weeks later at scale.

OTD 17 daysLab dip first-passReorder 11,000 pcs

Cut my third-party inspection budget in half — every PO carries an AQL report.

5 colorway tee plus jogger flat-lay mixed XS-XXL stack

ICP-A + C bridge

Berlin, EU · $3.8M ARR DTC Athleisure

5 SKU first launch · MOQ 100 split XS-XXL

Performance tees + joggers (5 colorways). MOQ 100 split per real size curve (20 pcs/size). Q1 2024 launch, sell-through 88% in 60 days.

MOQ 100 = 10088% sell-through2nd PO 5 weeks

Real MOQ math saved 5 SKU launches my last factory killed.

Trainer tee and branded zip-up jacket pair close-up

ICP-B · Studio Chain

Texas, US · 8-Location Fitness Chain

800-piece annual trainer uniform · 3-year reorder

Trainer tees + branded zip-up jackets. Color match across three reorder years confirmed by spectrophotometer log. Same SKU year 4 confirmed.

ΔE drift <0.8OTD 100%Year 4 confirmed

Year-over-year reorders match — no scrap, no member complaints.

Team jersey with back number 12 and surname print plus crest detail

ICP-D · Team Coach

Massachusetts, US · CrossFit Box Team

45-person team sublimated jerseys · roster CSV

Custom team set (number + name + crest), 35-day pre-season lead, sponsor block added on amend. Game-day OTD confirmed.

Pre-season 35 daysGame-day OTDSponsor block added

Roster CSV → sublimated jerseys in 35 days. Game-day ready.

Client voice

Sourcing Director Reviews of Our Manufacturing

What sourcing-side counterparts say after PO 3.

“

Two factories ago, batch-to-batch GSM drift was killing my Amazon BSR — 14% variance across one PO. We switched 3 SKUs to Berun. First PO: 4,200 pieces across 4 colors, OTD 17 days, lab dip passed on the first round. Reordered 11K pieces 6 weeks later. The pre-shipment AQL report comes with every PO — I cut my third-party inspection budget in half.

— Maya R., Senior Sourcing Director, Boulder CO athleisure brand ($18M ARR)

4-color performance leggings finished stack on warehouse shelf

“

Most factories quote MOQ 100 per SKU but actually mean 100 × 5 sizes = 500 units. That math killed 6 SKU launches for us in 2023. Berun split 100 across XS-XXL on our first PO — we launched 5 SKUs in Q1 2024 and hit 88% sell-through within 60 days. They send a monthly OTD report unprompted; I forward it to my CFO every month.

— Lukas H., Brand Founder, Berlin EU DTC athleisure ($3.8M ARR)

5-color tee flat-lay showing size split XS to XXL

“

Annual trainer uniform reorder is non-negotiable — if last year's batch and this year's batch don't match in person, members ask why. Berun's ΔE drift has stayed under 1.0 across three reorder years. We sized the new locations in year 4 and the spectrophotometer log proves the color is identical to year 1. No batch-to-batch surprises means I don't carry safety stock for color compensation.

— Tate W., Operations Director, 12-location Atlanta GA gym chain

3 trainer uniforms hung side-by-side showing color match across years

Reach & mix

Global Activewear Manufacturer Markets

Eight years, five regions, five buyer types.

Akarra Active Aspen Athletic Co. Berlin Mile Club Capella Sport Coastline Performance Forge Lab Athletics Granite Run Kindred Strength Meridian Move Northcrest Outdoor Sequoia Sweat Verdant Athletics

Markets shipped · % of 2024 volume

North America (US, CA)42%

Europe (UK, DE, FR, NL)28%

Oceania (AU, NZ)14%

Middle East (UAE, SA)10%

LATAM (MX, BR)6%

Client type mix · % of active accounts

Established sportswear / athleisure brand ($5-50M ARR)38%

DTC athleisure new brand (0-3 yr)22%

Fitness studio chain18%

Sports team / club / box12%

Wholesale distributor10%

FAQ

Custom Activewear Manufacturing FAQ

Eight questions sourcing directors and first-time founders ask before PO 1.

Sourcing director seated across from Berun rep at factory office desk reviewing tech-pack documents

How is MOQ split across sizes? Does 100 mean 100 per SKU or 100 × 5 sizes?

Our MOQ 100 is the total piece count for one SKU — not per size. You decide the size curve. If your sales data says XS=10% / S=20% / M=30% / L=25% / XL=15%, we cut 10/20/30/25/15 pieces. Most factories quote 100 per size, which means 500 pieces minimum once your size curve splits. We don't.

What's your sampling cost and turnaround time?

USD 45 per sample. 5 working days on fabric we have in stock; 12 working days if your fabric is custom or sourced. You get a full one-piece sample with pattern, fabric swatch, and lab dip color match. No bulk commitment required.

Related: Production Services Card 4 ↑

I don't have a tech-pack — can I still work with you?

Yes. Our 16 pattern-makers can build a tech-pack from a reference sample (a garment you already own) or a sketch. The pattern fee is USD 220 and it takes 7-14 days. After that we proceed exactly the same way as a client who brought their own tech-pack.

What does AQL 2.5 actually mean for my order?

AQL stands for Acceptable Quality Limit — the inspection sampling rate per ANSI/ASQ Z1.4. In plain English: we randomly inspect a statistically valid sample of pieces from your batch (typically 80-200 pieces depending on PO size) and check for defects. AQL 2.5 is the standard quality level retailers like Target and Costco require. We share the inspection report with every shipment.

What's your on-time delivery rate? Can I see evidence?

12-month rolling OTD is 92.4%. We log every shipment with promised date, actual date, and delay reason. The full log is reviewable under NDA for active buyers. We also send monthly OTD reports to repeat clients without being asked.

Difference between OEM, ODM, and Private Label?

OEM: you bring the tech-pack and the design — we cut and sew to your spec. ODM: you pick from our pattern library and customize color / fabric / logo — we skip the pattern-making cycle so you launch faster. Private Label: add your hangtag, care label, polybag and master carton on top of OEM or ODM. Private Label has no extra MOQ — it's an add-on.

Payment terms and FOB/CIF options?

Standard PO terms: 30% deposit on PO confirmation, 70% balance on BL (bill of lading) copy. FOB is default (you arrange shipping from our nearest port). CIF available on request (we arrange shipping to your destination port). For active buyers with repeat orders, we offer NET-30 on the balance.

How do you handle batch-to-batch color consistency?

Every PO starts with a lab dip — your approved color sample. We measure ΔE (color delta) against the lab dip using a spectrophotometer at three checkpoints: fabric receiving, mid-production, and pre-shipment. ΔE must stay ≤ 1.5. The lab dip is stored in your client master file and pulled for every reorder — so a reorder 6 months later matches the original.

Related: 5-Sec Disqualifier Stat 2 ↑

Have another question? Send it to sales@berunactivewear.com — we reply within 1 business day.