Effective custom company apparel is clothing your staff actually wear, that still looks right after months of washing, and that you can reorder in the same colour and fit. To get there, plan from the wear conditions backwards: decide where and how the garments will be worn, choose garment, fabric and logo method for that use, collect real sizes, and agree durability and reorder details before bulk production. Brand colours and logo artwork matter, but they come after these decisions.
Step 1: Define who wears it and where
- Customer-facing staff (retail, hospitality, reception): appearance, colour consistency and fit matter most.
- Active or warehouse roles: stretch, breathability and seam strength matter more than a crisp look.
- Events and promotional merch: one or two wears, so cost and decoration impact lead.
- Outdoor or cold settings: layering pieces such as hoodies or fleece.
If a role needs protective clothing, such as high-visibility or flame-resistant garments, that is regulated personal protective equipment. Buy it as certified PPE from a specialist; ordinary knit tees and hoodies are not a substitute.
Step 2: Choose garments and fabric for that use
| Use | Garment | Fabric points to consider |
|---|---|---|
| Front of house, office | Polo or tee | Cotton or cotton-rich blend for comfort; check colour fastness and shrinkage |
| Active, warehouse, fitness | Tee or performance top | Polyester or poly blends dry faster; cotton-elastane for stretch |
| Cold or outdoor | Hoodie or sweatshirt | Fleece or French terry weight chosen for the climate |
| Events, giveaways | Basic tee | A mid-weight jersey keeps cost down while printing well |
For the trade-offs, see poly-cotton blend vs 100% cotton tees and which fabric to choose for a custom hoodie.
Step 3: Pick the logo method
- Embroidery: durable and looks premium on polos, hoodies and heavier fabrics; can pucker on light jersey.
- Screen printing: cost-effective for larger quantities of one design, with set-up per colour.
- Heat transfer or DTF: suits small runs, many names or multi-colour artwork.
- Sublimation: works on light-coloured polyester, not on cotton.
More detail: embroidery vs screen print, sublimation vs screen print. Put the logo size and position on a drawing with a tolerance, so every size looks consistent (see logo placement tolerance).
Step 4: Get sizes right
- Order a size set and let a few staff try it before you collect sizes from everyone.
- Offer fitted and unisex cuts if your team needs them; one unisex cut rarely fits everyone well.
- Share the measurement chart with staff, not just S/M/L labels.
Step 5: Plan quantities and reorders
- Decide how many pieces each person gets, based on how often they work and how often garments are washed.
- Add a buffer for new hires and replacements, so you do not need a small rush order later.
- Keep the approved sample, fabric reference and colour standard, so reorders match the first batch.
- Ask how minimums apply per colour and per style before you add extra colours.
Step 6: Set durability and care requirements
Workwear is washed far more often than retail clothing. Agree a shrinkage limit tested to a named method, such as ISO 6330 washing with ISO 5077 measurement or AATCC TM135, and ask for test results on the bulk fabric (see writing a shrinkage limit). If garments will be laundered commercially, tell the supplier: it affects fabric, print and label choice.
Include a care label. If the garments are sold to consumers in the US, the Care Labeling Rule (16 CFR Part 423) applies; ISO 3758 symbols are widely used elsewhere. Even for garments given to staff, a correct care label helps them last.
Step 7: Build a realistic timeline
Work back from the date you need the garments: artwork and sample approval, fabric and production, inspection, and shipping. Ask the supplier for a dated plan rather than a single lead-time figure, and note that time spent waiting for your approvals adds directly to delivery. Allow extra time around factory holidays.
Company apparel with Knitwear Base
We produce custom T-shirts, hoodies and sportswear with your logo and labels, and can help with design. Send your quantities, logo files and the date you need the garments through our contact page.
Sources and further reading
- ISO 6330:2021, Domestic washing and drying procedures for textile testing
- ISO 5077:2007, Determination of dimensional change in washing and drying
- AATCC TM135, Dimensional Changes of Fabrics after Home Laundering
- eCFR, 16 CFR Part 423, Care Labeling of Textile Wearing Apparel
- ISO 3758:2023, Care labelling code using symbols
Rules and standards are summarised from their official pages for general guidance; this is not legal advice. Check the current version and the requirements of your own market before you rely on them.
