Start With Who Will Wear The Garments
The best size mix starts with the people wearing the apparel. A staff order for a warehouse team in Pinetown will usually need a different spread from a youth event in Umhlanga or a retail run for a brand in Pretoria. Before placing an order, ask for the age group, gender split if it matters, and whether the garments will be worn over other clothing.
For adult groups, a common mistake is ordering too many small sizes and not enough medium to extra large. For school groups, do not guess from one learner's size alone, because body shapes vary a lot. If the group is mixed, ask for a simple count by actual wearers rather than by department or branch.
- Adults: check chest, shoulder and preferred fit
- Teens and children: ask for current clothing size, not age only
- Promo wear: confirm if the garment must fit over a shirt or work uniform
Use A Simple Size Breakdown Formula
When you do not have exact wearer measurements, use a balanced size breakdown. For many adult runs, medium and large move fastest, while small and extra large still need decent cover. If you are planning for a mixed group in Durban's warmer areas or inland delivery, keep the range broad enough to reduce exchanges later.
A practical starting point for adult tees is often 1 small, 3 medium, 3 large, 2 extra large and 1 double extra large in every 10 pieces. For hoodies, shift one piece from small into large or extra large because many buyers prefer a roomier fit. This is not a hard rule, just a safe place to begin when no size history is available.
- 10 piece adult tee mix: 1 S, 3 M, 3 L, 2 XL, 1 2XL
- 10 piece hoodie mix: 1 S, 2 M, 3 L, 2 XL, 2 2XL
- Children's runs: split by actual ages or school size list whenever possible
For Events, Build In A Buffer
Event orders often need a buffer because late registrations, family members and staff changes happen right up to collection day. If you are planning for a sports day, choir trip, church conference or outdoor activation, allow extra medium and large sizes first, then a few pieces in the smaller and larger ends of the range. That gives you room to swap without holding too much dead stock.
In coastal areas like Amanzimtoti and Umhlanga, event organisers often run into last minute changes because of weather or transport delays. A small buffer is useful there as well. If your event is spread over several branches, we can help with size breakdown packs so each location gets the mix it needs without manual sorting on site.
- Keep 5 to 10 percent extra in fast moving sizes
- Ask for size labels on packs when handout is happening at different venues
- For fundraising events, allow for late joiners and volunteer staff
Retail Runs Need Real Sales History
If you are buying for resale, use your own sales records rather than general market guesses. Track which sizes sell first, which hang longest, and whether your customers like a close fit or a looser fit. A small brand in Westville may see different demand from a reseller in Phoenix because the customer base and price point are not the same.
When you are starting out and do not have history yet, order a wider spread, then review after the first selling cycle. Keep notes on returns, exchanges and the sizes that move when stock is displayed near the till. That information is more useful than broad assumptions, especially when you are planning seasonal stock for winter hoodies or summer tees.
- Review best sellers by size after every batch
- Record return reasons, not just the returned size
- Keep a separate note for fitted and relaxed styles
Check Garment Fit Before You Finalise
Different garment cuts can fit very differently even when the size label is the same. A straight cut tee, a relaxed hoodie and a slimmer fashion fit all sit on the body in a different way. For sublimation work, that matters because the final customer wants a print that looks right and feels comfortable too.
If you are unsure, compare the chest width and length of a sample against a garment the wearer already owns. This is especially helpful for corporate uniforms, school functions and promotional giveaways where one bad fit can create a lot of follow up calls. We can help with sample pack assembly so your team can check the feel before committing to bulk sizes.
Avoid Waste With Clear Packing Instructions
Once the size mix is confirmed, clear packing instructions make a big difference. Tell us whether you want sizes packed per person, per branch, per event team or by resale carton. Good instructions cut down on sorting time and reduce the chance of mix ups during nationwide dispatch from Pinetown.
If you are working with more than one branch, include the quantity per size and the split per delivery point. For example, a bulk order may need 20 medium, 25 large and 10 extra large, but broken into different branches in Hillcrest, Umhlanga and Amanzimtoti. If needed, we can also assist with collection scheduling, returns checking and size breakdown packs for easier handover.
- State total quantity first, then the size split
- Separate branch delivery notes from the main order
- Confirm any urgent cut offs before production or dispatch
