Why Do Some Tracksuit Brands Explode in Popularity—While Others Can’t Even Break Even?
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- Issue Time
- Nov 22,2025
Summary
Discover what drives the cost of screen-printed tracksuits—from fabric and printing setup to labor, hidden fees, and MOQ—so brands can reduce costs and boost margins.
Ever wondered why one factory quotes $15 for a screen-printed tracksuit set, while another offers $20 for what looks like the exact same product?
You might assume someone’s padding the numbers.
But the truth is simple:
Most brands don’t understand what really drives the cost of screen-printed tracksuits—from fabrics to finishing to printing techniques.
Today, let’s break it all down so you can price smart, negotiate confidently, and avoid the traps that quietly destroy margins.
1. Fabric & GSM: The #1 Price Driver in Tracksuits (Up to 55% of Your Cost!)
Tracksuits look simple… until you understand how fabric choices change everything.
Industry Reality :
Your fabric (and fabric weight) can account for up to 55% of your total cost.
Want heavyweight fleece? Brushed lining? Recycled poly? French terry?
Each upgrade adds dollars—fast.
Example :
A 280gsm polyester fleece tracksuit vs. a 350gsm cotton-blend version can differ by $3–$4 per set—before printing.
And don’t forget trims:
● Custom drawcords
● Metal tips
● Zippers
● Ribbing for cuffs and hems
Each tiny detail increases material usage and price.
Pro Tips :
● Request a full BOM (bill of materials) for transparency.
● Ask for two or three fabric alternatives—you’ll often save 10–20%.
● Confirm whether ribbing, pockets, and lining are included in the initial quote.
2. Screen Printing Complexity: The Silent Cost Multiplier
Screen printing seems cheap—until you understand how pricing really works.
Every color = a new screen.
Every screen = more cost.
Special inks = even more.
Real Example :
A two-color logo on a tracksuit may only cost $0.30–$0.50.
Add reflective ink + a back print + sleeve print?
Your printing cost jumps from $0.50 to $2.50+ instantly.
Industry Data :
More than 70% of screen printing costs come from setup, not ink—meaning:
➡ Multiple prints + low quantities = expensive.
Action Steps :
● Consolidate print areas (one large print is cheaper than three small ones).
● Stick with 1–2 colors for scale production.
● Avoid special inks unless it’s a premium line.
● Ask for CMYK vs. spot-color options to compare prices.
3. Workmanship & Construction: Tracksuits Are Labor-Heavy
Tracksuits require :
● Panels
● Pockets
● Rib cuffs
● Elastic waistbands
● Hood or collar construction
● Lining (sometimes)
More pieces = more labor.
Example :
A basic tracksuit requires ~40 minutes of sewing time.
A complex one with rib-panels, zip pockets, and triple-stitched seams?
Up to 65 minutes—which means 30–40% higher labor cost.
Data Point :
Workmanship can make up 30–35% of a tracksuit’s total cost.
Brand Tips :
● Compare simple vs. complex versions of the same tracksuit.
● Reduce unnecessary panels to cut 10–15% labor cost.
● Avoid too many color-blocked panels unless it’s a flagship design.
4. Hidden Costs: Packaging, Freight, Duties & MOQ Traps
Thinking ex-factory price is all you’ll pay?
Think again.
Hidden cost examples :
● Custom polybags: $0.15
● Hangtags: $0.05–$0.08
● Freight: $0.40–$0.90 per set depending on port
● Duties: varies by region (some up to 25%!)
● Carton size & weight (tracksuits are bulky!)
Real Case :
A brand ordering 2,500 tracksuits had their landed cost jump $0.70 per set due to freight and port charges—cutting margin by 18%.
What to Do :
Always calculate landed cost, not just factory price.
Know the difference between FOB, EXW, and CIF.
Choose shipping ports strategically—Guangzhou vs. Ningbo can mean big cost differences.
5. Quantity & Print Setup: The Ultimate Lever for Screen-Printed Tracksuit Pricing
Screen printing has one fixed truth:
Higher MOQ → Lower per-unit cost
Why?
Because printing setup fees are spread across more pieces.
Example :
A 2-color print:
● At 300 sets → setup adds $0.80 per set
● At 2,000 sets → setup drops to $0.10 per set
That’s a $0.70 difference just from order quantity.
Best Practices :
● Merge colorways so total print quantity is higher.
● Offer basic and premium versions with different print complexities.
● Lock in repeat orders so setup fees decrease in batch 2 and batch 3.
6. Take Action: Break Down Your Next Screen-Printed Tracksuit Quote
Stop looking at the final price only.
Next time you negotiate, ask your factory for a complete breakdown:
● Fabric & GSM cost (itemized)
● Trims list
● Screen printing setup + per-color cost
● Labor per piece
● Packaging charges
● Freight estimate
● Landed cost calculation
This sheet alone can save you:
✔ 5% by adjusting GSM
✔ 8% by simplifying printing
✔ 10–20% by merging quantities and reducing colorways
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