Shirts are a staple in modern wardrobes, catering to various styles, occasions, and functional needs. The production cost of shirts involves several factors, including materials, labor, manufacturing processes, and logistics. Here’s an overview of the different types of shirts, their retail prices, popularity, and production details.
How Shirts are Produced
Fabric Selection and Preparation
The production of shirts begins with the careful selection of fabric. Common materials include cotton, polyester, or blends, each chosen for its texture, durability, and comfort. The fabric is then prepared by washing and treating it to remove impurities and improve its quality. This preparation process ensures that the material is clean, pre-shrunk, and ready for cutting. In some cases, the fabric is also dyed or printed with patterns according to design specifications. This stage sets the foundation for the quality and appearance of the final shirt.
Pattern Making and Cutting
Once the fabric is prepared, pattern making and cutting follow. Designers create patterns based on the shirt’s size and style, which are then used as templates. These patterns are laid out on the fabric, ensuring minimal waste while maximizing the use of material. The fabric is then cut into various pieces, including the front, back, sleeves, collar, and cuffs. Precision is crucial at this stage, as accurate cutting ensures that the pieces fit together seamlessly during assembly, maintaining the shirt’s intended shape and fit.
Assembly and Stitching
The cut fabric pieces are then assembled and stitched together. This process typically begins with attaching the front and back panels, followed by the sleeves, collar, and cuffs. Skilled workers or automated sewing machines are used to stitch the pieces together with precision. The seams must be strong and durable, with attention to detail to ensure a clean finish. Additional features, such as buttonholes, pockets, and pleats, are added during this stage. Proper stitching is essential to the shirt’s durability and appearance, contributing to its overall quality.
Finishing and Quality Control
After assembly, the shirt undergoes finishing processes to enhance its appearance and feel. This includes ironing or pressing to remove wrinkles, attaching labels, and sometimes adding decorative elements. The shirt is then inspected for quality control, where each piece is checked for defects such as loose threads, uneven stitching, or fabric flaws. Any issues are corrected before the shirt is packaged. Quality control ensures that only shirts meeting the required standards are shipped to retailers or customers, maintaining the brand’s reputation for high-quality products.
Shirt Production Cost Distribution
Shirt production costs can be distributed across several key components. Below is a general breakdown of how costs might be distributed in the production of a shirt. The actual percentages can vary depending on the type of shirt, the scale of production, and the region.
- Material Costs (45% – 55%)
- Fabric: 35% – 45% of total cost
- Thread, Labels, and Tags: 5% – 10% of total cost
- Labor Costs (20% – 30%)
- Cutting and Sewing: 15% – 25% of total cost
- Finishing: 5% of total cost
- Overhead Costs (10% – 15%)
- Machinery Depreciation: 5% – 7% of total cost
- Utilities and Rent: 5% – 8% of total cost
- Transportation and Logistics (5% – 10%)
- Shipping Raw Materials: 2% – 4% of total cost
- Distribution of Finished Product: 3% – 6% of total cost
- Miscellaneous Costs (5% – 10%)
- Quality Control: 3% – 5% of total cost
- Design and Development: 2% – 5% of total cost
Types of Shirts
1. Dress Shirts
Description
Dress shirts are tailored garments typically worn with suits or formal wear. They are characterized by a stiff collar, long sleeves with cuffs, and a button-down front. Dress shirts are made from fine fabrics such as cotton, silk, or linen and come in various styles including solid colors, stripes, and checks.
Popular Brands
| Brand | Established | Location |
|---|---|---|
| Brooks Brothers | 1818 | New York, USA |
| Thomas Pink | 1984 | London, UK |
| Charles Tyrwhitt | 1986 | London, UK |
| Turnbull & Asser | 1885 | London, UK |
| Eton Shirts | 1928 | Gånghester, Sweden |
Retail Price and Popularity
- Average Retail Price on Amazon: $50 – $150
- Popularity: Dress shirts remain highly popular due to their necessity in professional and formal settings.
Production Details
- White Label Production Cost in China: $8 – $15 per shirt
- Product Weight: 250 – 300 grams
- Minimum Order Quantity: 500 units
- Major Materials: 100% cotton, cotton blends, silk, linen
2. Polo Shirts
Description
Polo shirts are casual, short-sleeved shirts with a collar and a placket with two or three buttons. Made from knitted fabrics such as piqué or jersey, polo shirts are versatile and can be worn in both casual and semi-formal settings.
Popular Brands
| Brand | Established | Location |
|---|---|---|
| Ralph Lauren | 1967 | New York, USA |
| Lacoste | 1933 | Troyes, France |
| Fred Perry | 1952 | London, UK |
| Hugo Boss | 1924 | Metzingen, Germany |
| Tommy Hilfiger | 1985 | New York, USA |
Retail Price and Popularity
- Average Retail Price on Amazon: $30 – $90
- Popularity: Polo shirts are widely popular for their comfort and style versatility, making them a favorite in casual and semi-formal attire.
Production Details
- White Label Production Cost in China: $5 – $10 per shirt
- Product Weight: 200 – 250 grams
- Minimum Order Quantity: 300 units
- Major Materials: 100% cotton, cotton blends, polyester blends
3. T-Shirts
Description
T-shirts are basic garments with short sleeves and a round neckline, known for their comfort and casual style. They come in various designs, including solid colors, graphics, and logos.
Popular Brands
| Brand | Established | Location |
|---|---|---|
| Hanes | 1901 | Winston-Salem, USA |
| Fruit of the Loom | 1851 | Bowling Green, USA |
| Gildan | 1984 | Montreal, Canada |
| Uniqlo | 1949 | Yamaguchi, Japan |
| American Apparel | 1989 | Los Angeles, USA |
Retail Price and Popularity
- Average Retail Price on Amazon: $10 – $30
- Popularity: T-shirts are extremely popular across all age groups for their comfort, affordability, and ease of customization.
Production Details
- White Label Production Cost in China: $2 – $5 per shirt
- Product Weight: 150 – 200 grams
- Minimum Order Quantity: 1000 units
- Major Materials: 100% cotton, cotton blends, polyester blends
4. Henley Shirts
Description
Henley shirts are a collarless version of polo shirts with a placket of several buttons, typically made from soft, knitted fabrics. They are a popular choice for casual wear, offering a blend of comfort and style.
Popular Brands
| Brand | Established | Location |
|---|---|---|
| J.Crew | 1947 | New York, USA |
| Banana Republic | 1978 | San Francisco, USA |
| L.L. Bean | 1912 | Freeport, USA |
| Ralph Lauren | 1967 | New York, USA |
| Tommy Hilfiger | 1985 | New York, USA |
Retail Price and Popularity
- Average Retail Price on Amazon: $20 – $60
- Popularity: Henley shirts are popular for their versatile style, bridging the gap between casual and slightly more polished looks.
Production Details
- White Label Production Cost in China: $4 – $7 per shirt
- Product Weight: 180 – 220 grams
- Minimum Order Quantity: 300 units
- Major Materials: 100% cotton, cotton blends, wool blends
5. Flannel Shirts
Description
Flannel shirts are known for their soft, warm fabric and typically feature a plaid or tartan pattern. They are popular for casual and outdoor wear, especially in colder climates.
Popular Brands
| Brand | Established | Location |
|---|---|---|
| Pendleton | 1909 | Portland, USA |
| L.L. Bean | 1912 | Freeport, USA |
| Patagonia | 1973 | Ventura, USA |
| Woolrich | 1830 | Woolrich, USA |
| Filson | 1897 | Seattle, USA |
Retail Price and Popularity
- Average Retail Price on Amazon: $40 – $100
- Popularity: Flannel shirts are highly popular in colder regions and among those who appreciate the rugged, outdoorsy aesthetic.
Production Details
- White Label Production Cost in China: $8 – $12 per shirt
- Product Weight: 300 – 350 grams
- Minimum Order Quantity: 500 units
- Major Materials: 100% cotton, wool blends, polyester blends
6. Hawaiian Shirts
Description
Hawaiian shirts, also known as Aloha shirts, are known for their bright, colorful patterns and lightweight fabrics. They are typically worn in casual, warm-weather settings.
Popular Brands
| Brand | Established | Location |
|---|---|---|
| Reyn Spooner | 1956 | Honolulu, USA |
| Tori Richard | 1953 | Honolulu, USA |
| Tommy Bahama | 1992 | Seattle, USA |
| Jams World | 1964 | Honolulu, USA |
| RJC Clothing | 1953 | Honolulu, USA |
Retail Price and Popularity
- Average Retail Price on Amazon: $30 – $70
- Popularity: Hawaiian shirts are popular for their casual, laid-back vibe, making them a staple for vacations and warm climates.
Production Details
- White Label Production Cost in China: $5 – $8 per shirt
- Product Weight: 150 – 200 grams
- Minimum Order Quantity: 300 units
- Major Materials: Rayon, cotton, polyester blends
7. Chambray Shirts
Description
Chambray shirts resemble denim shirts but are lighter and softer. They are made from a lightweight woven fabric and are suitable for casual and smart-casual wear.
Popular Brands
| Brand | Established | Location |
|---|---|---|
| J.Crew | 1947 | New York, USA |
| Levi’s | 1853 | San Francisco, USA |
| Ralph Lauren | 1967 | New York, USA |
| Madewell | 1937 | New York, USA |
| Everlane | 2010 | San Francisco, USA |
Retail Price and Popularity
- Average Retail Price on Amazon: $40 – $80
- Popularity: Chambray shirts are popular for their versatility and stylish yet casual appearance, making them a favorite in smart-casual wardrobes.
Production Details
- White Label Production Cost in China: $6 – $9 per shirt
- Product Weight: 250 – 300 grams
- Minimum Order Quantity: 300 units
- Major Materials: 100% cotton
8. Denim Shirts
Description
Denim shirts are sturdy and durable, made from the same fabric as jeans. They are often worn in casual and rugged styles and can be paired with various outfits.
Popular Brands
| Brand | Established | Location |
|---|---|---|
| Levi’s | 1853 | San Francisco, USA |
| Wrangler | 1947 | Greensboro, USA |
| Lee | 1889 | Merriam, USA |
| Ralph Lauren | 1967 | New York, USA |
| Diesel | 1978 | Breganze, Italy |
Retail Price and Popularity
- Average Retail Price on Amazon: $50 – $100
- Popularity: Denim shirts are popular for their classic, rugged appeal and versatility in casual and semi-casual settings.
Production Details
- White Label Production Cost in China: $7 – $12 per shirt
- Product Weight: 350 – 400 grams
- Minimum Order Quantity: 500 units
- Major Materials: 100% cotton, denim
9. Oxford Shirts
Description
Oxford shirts are a staple in both casual and formal wardrobes. Made from Oxford cloth, they feature a button-down collar and a classic, slightly textured weave. These shirts are versatile and can be dressed up or down.
Popular Brands
| Brand | Established | Location |
|---|---|---|
| Brooks Brothers | 1818 | New York, USA |
| Ralph Lauren | 1967 | New York, USA |
| J.Crew | 1947 | New York, USA |
| Uniqlo | 1949 | Yamaguchi, Japan |
| Everlane | 2010 | San Francisco, USA |
Retail Price and Popularity
- Average Retail Price on Amazon: $30 – $80
- Popularity: Oxford shirts are highly popular due to their versatility and timeless style, making them a staple in both casual and formal wardrobes.
Production Details
- White Label Production Cost in China: $6 – $10 per shirt
- Product Weight: 250 – 300 grams
- Minimum Order Quantity: 300 units
- Major Materials: 100% cotton, cotton blends
