How Startups Can Prepare for Their First Production Run.
The gap between a design idea and finished garments in a warehouse is larger than most first-time brand founders anticipate. This guide walks through the ten things to prepare - so you don't learn them the expensive way.
General industry knowledge • Reviewed by Fenalt editorial team
Step-by-Step Guide
10 Steps to Prepare for Your First Production Run
Finalise Your Designs Before Contacting Manufacturers
The most expensive thing a brand can do is involve a manufacturer before designs are settled. Every design change after sampling begins costs time and money. Have a clear, finalised design direction - even if not yet in full tech pack format - before making manufacturer contact.
Create or Commission a Tech Pack
A tech pack is the document manufacturers work from. Without one, you cannot get an accurate quote, a consistent sample, or a reliable production outcome. If you cannot create one yourself, commission a technical designer or use a manufacturer who offers tech pack development support.
Determine a Realistic Order Quantity
Your first production order quantity should be informed by realistic demand forecasting - not wishful thinking. Overproducing a first run is a common and costly mistake. Consider starting with a smaller pilot batch to validate market response before scaling.
Research and Verify Your Manufacturer
Do not select a manufacturer based on price alone or on an attractive website. Request samples of their existing work, check references, understand their MOQ and QC process, and confirm they have genuine experience with your specific product type.
Build a Realistic Timeline
Most first-time brands underestimate the full timeline. From initial manufacturer contact to goods in your warehouse, a realistic minimum for a first custom production run is 16 to 24 weeks - accounting for design finalisation, tech pack creation, fabric sourcing, 2 to 3 sample rounds, bulk production, and freight.
Prepare Your Budget Including All Costs
Production cost is only part of the total. Also budget for: sampling fees, shipping and freight, import duties and customs entry, label and packaging production, inspection costs, and a contingency for revision rounds or timeline slippage.
Understand the Sampling Process Before It Starts
Expect multiple sample rounds. Know what you are checking in each sample - fit, fabric, construction, label placement - and be prepared to provide specific, written feedback rather than general impressions. Unclear feedback prolongs revision cycles.
Do Not Rush Sample Sign-Off
The approved pre-production sample becomes the quality standard for your entire bulk order. Sign off only when you are genuinely satisfied - every issue you overlook in sampling will be replicated across your entire run.
Plan for Quality Inspection Before Shipment
Arrange for a pre-shipment quality inspection before your bulk order ships. This is your last opportunity to identify and resolve quality issues before goods leave the factory. Once goods ship, rectification options are significantly more limited and expensive.
Understand Your Import Requirements
Before goods arrive, confirm: import duty rates for your garment categories and country of origin; customs entry requirements and your import broker's role; and any labelling or fibre content requirements mandated in your destination market.
Avoid These
Common Mistakes on a First Production Run
Committing to bulk production before approving a sample
Underestimating the total timeline - especially fabric sourcing lead times
Providing vague or verbal instructions instead of a tech pack
Overproducing on a first run without market validation
Ignoring import duty and freight cost in the total unit economics calculation
Choosing a manufacturer primarily on price without verifying capability
Questions
Frequently Asked Questions
How long does a first production run realistically take?
For a brand new to a manufacturer with custom cut-and-sew garments, allow a minimum of 16 to 20 weeks from initial brief to goods received. This includes: 2 to 4 weeks for design and tech pack finalisation, 4 to 6 weeks for sampling and approval, 4 to 6 weeks for bulk production, and 3 to 5 weeks for sea freight. Air freight reduces shipping time but significantly increases cost. Add 4 to 8 weeks buffer for an unexpectedly smooth process on a first project.
Can Fenalt help with a brand's first production run?
Yes. Fenalt specialises in supporting independent brands, emerging designers, and startups through their first production projects in Bangladesh - including tech pack review, sampling, production oversight, QC, and export coordination. Brands can submit a project brief directly through the intake form.
Do I need a full tech pack before contacting a manufacturer?
A complete tech pack is strongly recommended before submission for best results. However, some manufacturers and production management partners (including Fenalt) offer tech pack development support for brands who have a design concept and reference garment but lack the technical documentation. Submitting without any tech pack documentation will limit the accuracy of any initial quote and significantly extends the sampling process.
What is the minimum viable order quantity for a first production run?
This varies by manufacturer and product category. For cut-and-sew knit garments (hoodies, sweatshirts, t-shirts), many specialist manufacturers accept starting orders from 50 to 100 units per style. However, fabric mill minimums, label setup costs, and per-unit economics often make orders below 100 units difficult to cost effectively. A realistic first-run MOQ for most brands is 100 to 300 units per style.
What costs should I budget for beyond per-unit manufacturing cost?
Full landed cost per unit includes: FOB manufacturing price + sampling fees (typically $30–$300 per sample type depending on complexity) + sea or air freight + import duty (varies by HS code and destination country, commonly 10–20% for garments) + customs broker fees + warehousing upon arrival + any pre-shipment inspection fees. Brands often underestimate total landed cost by 30–50% when planning from manufacturing price alone.
What is the biggest mistake first-time brands make in production?
Committing to bulk production before approving a pre-production sample. This is the single most avoidable cause of bulk order defects. The PP sample approval is the contractual quality gate that defines the standard for the entire run. Brands who feel time pressure and approve a PP sample with known unresolved issues - or worse, begin bulk cutting before a PP sample is made - are accepting full financial responsibility for whatever defects result.
Ready to start your first production run?
Fenalt guides brands through every stage of their first production project - from sampling to export - with a dedicated Dhaka operations team.
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