Loungewear Manufacturer

By cutting both halves from the same dye lot, planned that way from the start rather than fixed afterwards. This is the defining risk of the category and it is worth understanding why it happens. Fabric is dyed in batches, and two batches of the same colour reference are never identical — they are within commercial tolerance of each other, which is fine for unrelated garments and not fine for two pieces a customer holds side by side. If a top and a bottom are made from different lots, the mismatch is usually invisible on screen and obvious in daylight, which is exactly the situation that produces a return. We book the full fabric requirement for a set into one lot and cut both pieces from it. It is a planning discipline rather than a technical trick, and it is standard on every set we make.

Modal, or a cotton-modal blend, for anything drape-led. Modal is a cellulose fibre with a smoother surface than cotton, so it feels slicker and cooler in the hand, drapes more fluidly, and — the part that matters most — keeps that softness through repeated washing. Much cheap loungewear uses cotton jersey treated with a softening finish, which feels excellent in the shop and progressively washes out, leaving a flatter, coarser fabric within a few laundry cycles. That is a very common cause of poor repeat purchase, because the customer's experience of the product gets worse rather than better. For warmth rather than drape, brushed-back fleece and French terry at 280 to 340 GSM give the cosy weight people associate with loungewear. We will send fabric swatches before you commit.

It will if the fabric was compacted and relaxed before cutting, and it will not if it was cut straight off the roll. Knitted fabric leaves the mill under tension. If it is cut in that state, the garment relaxes in its first wash and shrinks — commonly by several percent, and rarely evenly, so a set can shrink differently in the top and the bottom and stop matching. Compacting and relaxing the fabric before cutting releases that tension in advance, so the shrinkage becomes small and predictable, and we build the remaining allowance into the pattern. We can also wash-test your sample and give you the measurements before and after, so what you approve is what your customer still has after a month rather than what it measured on day one.

Yes. The 100-piece minimum applies per style and per colour, and a top and a bottom are two different styles, so a set in one colour is 200 pieces in total. Plenty of brands start with a single strong piece rather than a full set, which is a reasonable way to test a fabric and a fit before committing to the pair. If you do intend to sell them as a set later, tell us at the start, because we will then plan the fabric booking so a matching bottom can be cut from the same lot when you reorder. Without that heads-up the second piece is a fresh dye lot and matching becomes a gamble rather than a plan.

Between 280 and 340 GSM for fleece or French terry, depending on whether you want cosy or lightweight. Below about 250 GSM the fabric starts to feel thin and can go slightly translucent in pale colours, which matters more on bottoms than on tops. Above roughly 360 GSM the garment becomes heavy and slow to dry, which people find less comfortable for actual lounging even though it feels impressive in the hand. The 300 to 320 GSM range is where most successful lounge bottoms sit. For drape-led styles in modal the numbers are different and lower, because the fabric is doing a different job. As with everything, the most reliable route is to send a garment you like and let us measure it rather than choosing from a chart.