How Much Do Shirts Cost to Manufacture?

Trying to figure out how much it actually costs to manufacture shirts — especially with suppliers in Tirupur?

The average cost of manufacturing a shirt in Tirupur¹ ranges between $1.50 and $4.00 per unit, depending on fabric, print type, customizations, and order volume.

In this guide, I’ll break down the real cost components, walk you through how top manufacturers in Tirupur work, and offer strategies to manage your budget without sacrificing quality.

Main Factors That Influence Shirt Manufacturing Cost?

Sewing Process

There’s no flat rate for manufacturing shirts. Small differences in fabric, print size, or label details can create major cost changes.

The most important cost drivers include fabric choice², stitching quality³, decoration method⁴, and your order quantity⁵.

Knowing what impacts pricing will help you design smarter and avoid unnecessary expenses.

How Do Fabric Types (Cotton, Organic Cotton, Blends) Impact Cost?

Fabric accounts for 50%–70% of the total cost of a shirt.

Different cotton types, blend compositions, GSM (weight), and treatments all influence final pricing.

Common Fabric Types and Estimated Cost per Shirt:

Fabric Type	GSM Range	Avg. Cost/Shirt (USD)	Description
Carded Cotton	140–160	$1.40 – $1.80	Budget-friendly, suitable for giveaways
Combed Cotton	160–200	$1.70 – $2.30	Smooth, durable, great for retail use
Organic Cotton (GOTS)	160–200	$2.50 – $3.50	Eco-certified, soft and premium
Cotton-Poly Blend (60/40)	140–180	$1.50 – $2.20	Wrinkle-resistant, affordable
Tri-Blend (C/P/R)	150–180	$2.20 – $3.00	Super soft, fashion and activewear

When requesting quotes, be specific: state GSM, yarn quality (combed or carded), and whether pre-washing or enzyme finishing is required. This prevents misunderstandings and low-grade substitutions.

Why Do Printing, Embroidery, and Customization Raise Prices?

Decoration and branding add significant value — but also increase cost.

Each design location, color count, and technique (like embroidery or heat transfer) adds to the total cost per shirt.

Popular Customization Options and Additional Cost:

Method	Add-on Cost (USD)	Notes
Screen Printing (1-color)	$0.15 – $0.40	Each color and location increases the cost
DTG Printing	$0.80 – $1.50	Suitable for small orders and color images
Embroidery	$0.60 – $1.20	Pricing depends on stitch count and size
Neck Label Print	$0.05 – $0.10	Private label friendly, cost-effective
Custom Hang Tags	$0.08 – $0.20	Includes punching, tying, and tagging

If your budget is tight, go with a single-color screen print and printed neck label. Avoid complex multi-location artwork or large embroidery patches to reduce overall cost.

Average Manufacturing Cost with Tirupur Shirt Manufacturers?

Tirupur is India’s knitwear capital, known for its cotton expertise, competitive pricing, and willingness to handle small-batch custom orders.

Factories in Tirupur are especially suited to private label buyers who want flexibility, quality control, and transparent pricing.

What Is the Cost Per Shirt for Small vs. Bulk Orders in Tirupur?

Below are sample price ranges based on a basic tee with 180 GSM combed cotton and one-color screen print:

Order Volume	Cost per Shirt (USD)
100 pcs	$2.60 – $3.30
300 pcs	$2.30 – $2.80
1,000 pcs	$2.00 – $2.40
5,000+ pcs	$1.70 – $2.00

Larger volumes allow for:

• Efficient fabric usage
• Fewer machine stoppages
• Better labor utilization
• Lower print setup cost per unit

How Do Export-Grade Shirts Differ in Pricing from Local Market Shirts?

Factories in Tirupur often produce for both export and domestic markets — but the standards are very different.

Export-grade shirts use more stable yarn, better finishing, and follow strict QC, which makes them 10%–30% more expensive.

Feature	Export-Grade Shirt	Local Market Shirt
Fabric Quality	Combed, consistent GSM	Carded, lower consistency
Stitching	Twin-needle, shoulder tape	Single-needle, looser seams
Finishing	Bio-washed, pre-shrunk	Often skipped
Packaging	Individual polybag, tags	Bulk-packed, minimal tags

If you’re targeting North America, Europe, or Australia, export-grade standards are the better long-term investment.

Comparing Tirupur with Other Global Manufacturing Hubs?

Many buyers compare Tirupur with manufacturers in China, Bangladesh, or Vietnam. The right choice depends on your priorities.

Tirupur offers a great balance between flexibility, quality, and cost — especially for cotton-based private label brands.

Are Shirts from Tirupur Cheaper Than Those from China or Bangladesh?

Here’s a rough comparison for a 1,000-piece order with basic specs:

Country	Unit Price (USD)	MOQ Flexibility	Lead Time
Tirupur	$2.00 – $2.40	100 pcs	18–25 days
Bangladesh	$1.60 – $2.10	1,000 pcs+	25–40 days
China	$2.40 – $3.00	300–500 pcs+	20–30 days
Vietnam	$2.20 – $2.80	300–1,000 pcs	25–35 days

Tirupur is ideal when you need lower MOQs, faster sampling, and flexibility across SKUs.

Does Tirupur Offer Better Quality at a Competitive Price Point?

Yes. Many of Tirupur’s top factories produce for global brands.

You get reliable cotton sourcing, strong production consistency, and better customer service — all at a price point suitable for mid-sized brands.

Benefits include:

• Direct factory communication
• Faster sampling and reorders
• Print, label, and packing done in one place
• Better handling of custom requirements

This makes Tirupur a great fit for growing apparel brands who care about both quality and margins.

Hidden Costs in Shirt Manufacturing?

Many buyers overlook secondary costs that appear after the manufacturing quote.

Total landed cost includes logistics, import duties, and local handling — often adding 20%–40% on top of factory prices.

What Role Do Shipping, Taxes, and Customs Play in Total Cost?

Once your shirts leave the factory, there are several extra charges to account for:

• Air freight (200 kg): $3.50–$6.00/kg
• Sea freight (LCL): $90–$150 per CBM
• Customs duty (e.g., USA): 8%–16% of invoice
• Clearance and brokerage: $100–$250
• Domestic transport and warehousing: Varies

To avoid confusion, clarify whether you’re being quoted FOB or CIF, and build logistics cost into your retail pricing model.

How Does MOQ (Minimum Order Quantity) Affect the Final Price?

The lower your order size, the higher your unit cost.

Factories incur the same setup time and machine prep, regardless of volume — which makes small runs more expensive per unit.

Quantity	Estimated Cost per Shirt (USD)
100 pcs	$2.80 – $3.30
500 pcs	$2.30 – $2.60
1,000 pcs	$2.00 – $2.40
5,000 pcs	$1.70 – $2.00

Ask if the factory allows color or size combinations within the MOQ to increase flexibility.

Tips to Reduce Shirt Manufacturing Cost with Tirupur Manufacturers?

Cutting costs doesn’t have to mean cutting corners.

With better planning and communication, you can reduce waste, simplify production, and secure more favorable pricing.

How to Negotiate Better Rates Without Sacrificing Quality?

Professional buyers get better deals because they make life easier for the factory.

The more clearly you present your requirements, the more confident your supplier is — which improves trust and price.

Best practices:

• Provide tech packs or clear spec sheets
• Group styles with the same fabric and color
• Use repeat orders to request discounts
• Ask for suggestions on saving cost (fewer colorways, simplified packaging)
• Offer longer lead time in exchange for better pricing

Avoid last-minute changes, unclear references, or scattered communication — these increase supplier risk and often lead to higher quotes.

Which Certifications and Partnerships Ensure Cost-Effective Production?

Choosing certified manufacturers reduces long-term risk.

Better systems mean fewer defects, more consistency, and less time wasted fixing mistakes.

Key certifications:

Certification	What It Ensures
GOTS	Organic fabric and sustainable processing
OEKO-TEX	No harmful chemicals in the garment
WRAP / SA8000	Ethical labor and safe working conditions
ISO 9001	Quality management systems in production

Always request current certification documents and check the coverage scope — some only apply to specific units or processes.

Conclusion

Manufacturing shirts in Tirupur typically costs between $1.50 and $4.00 per piece. But what you pay depends on dozens of factors — fabric, print, order volume, and your supplier relationship. By understanding what drives the cost and asking the right questions, you can produce high-quality shirts that fit your brand and budget — without surprises.

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