Yoga wear sourcing guide

A yoga range is not a single product. It is a fabric decision, a fit decision and a colour decision repeated across several styles — and each of those decisions moves the price, the minimum quantity and the calendar. Getting them in the right order is most of the work.

1. Fabric and weight decide everything downstream

Start with the fabric, because it sets the floor on price and the ceiling on fit. Three families cover most of the market:

• Nylon–spandex (typically 220–300 gsm) — the softest hand feel and the best recovery, which is why it is the default for squat-proof leggings and for bras that need to hold shape.
• Recycled polyester–spandex (250–320 gsm) — more durable and generally cheaper per kilo, with a slightly drier hand feel. A common choice where a recycled-content story matters to the customer.
• Seamless circular knits — knitted to shape rather than cut and sewn, which removes side seams and lets you build contour zones and ventilation into the knit itself.

Weight works in the opposite direction to comfort: heavier fabric is more opaque and more compressive, but slower to dry and warmer. A 240 gsm legging and a 300 gsm legging from the same mill are different products for different markets, and the difference shows up as both cost and customer feedback.

2. Fit and sizing: where most returns come from

Sizing is the single most common source of complaint in activewear, and it is fully controllable before production:

• Decide the size chart before sampling. If you do not have one, build it from graded measurements for your market rather than inheriting the factory's default chart.
• Be explicit about rise and length. High-rise versus mid-rise, and 7/8 versus full length, are the two variables buyers most often leave implied and then query on the sample.
• Test on a body, not on a table. A sample photographed flat looks very different from the same garment worn and moved in. Any leg-length or waistband slippage shows up immediately in wear testing.
• Consider inseam and gusset construction together. A well-constructed gusset is the difference between a legging that is comfortable for an hour and one that works for a two-hour class.

3. MOQ and sampling: the honest version

Minimum order quantity is not one number. It is the sum of separate minimums — fabric dyeing, knitting or weaving, cutting, and any custom trim such as a printed label or a branded zip pull. A style in a stock fabric can often run smaller than the same style in a new colour.

Two practical points:

• Ask the MOQ per colour, not per style. A range of six styles in one colourway is a very different order from six styles in six colourways.
• Ask what a trial order costs in total, not just per unit. A small first run is usually viable; it simply carries a higher unit cost because the setup is spread over fewer pieces.

Sampling follows a fixed sequence that protects you: reference and brief, development of the sample, photographs for your written approval, and only then bulk. Nothing should be cut before that approval, and any supplier who wants to skip it is asking you to carry their risk.

4. Quality checks worth insisting on

• In-line checks during sewing — catching a seam or sizing fault while the line is still running is far cheaper than sorting finished cartons.
• A final inspection against the approved sample — measurements, stitch quality, colour consistency against the approved swatch, and labelling accuracy.
• Stretch and recovery testing — particularly important for leggings, where poor recovery shows up as bagging at the knee and waist after a few wears.
• A measurement report with the shipment — for a multi-style order it is the fastest way to resolve any query at destination.

5. Branding and packaging are part of the product

For a private-label range, the label, the hangtag and the polybag are what the customer meets first. Decide them while the sample is in development, not after bulk production, because they change the packing plan:

• Woven labels versus heat-transfer or printed logos — woven reads as premium; printed is faster to change between styles.
• Hangtags and barcodes — specify the barcode format your fulfilment centre or retailer actually scans.
• Retail-ready versus bulk packing — polybag, header card, retail box or a rigid gift box changes carton dimensions, which changes freight cost.

6. Lead times: plan backwards from your launch

A realistic timeline for a new private-label style usually looks like this:

• Brief and development proposal — a few days, assuming the brief is complete.
• Development sample — around two to three weeks, longer if new fabric has to be knitted.
• Your approval and any revision — allow a week; revisions are normal and cheaper than guessing.
• Bulk production — depends on quantity and whether the fabric is in stock or dyed to order.
• Freight — express is days, air freight is about a week, sea freight is measured in weeks and needs booking ahead of the peak season.

Work backwards from the date the goods need to be on sale, not from the date you place the order. The two dates that most often slip are fabric dyeing and sea freight booking, and both are avoidable with early decisions.