Custom Branded Apparel for a Leading American Craft Brewery
Project Overview
Client— Independent craft brewery, United States
Relationship— Returning client with multiple seasonal orders
Product Categories— Pullover hoodies, crewneck sweatshirts, work shirts, zip-up hoodies, flannel shirts, printed shirts
Size Range— S to 4XL, custom size chart based on Russell Athletic standards
Key Fabrics— 300GSM 100% cotton fleece, 280GSM 100% cotton French terry, poly-cotton poplin, flannel
Customization— Water-based screen printing, custom embroidery, heat transfer neck labels, contrast stitching, lace-up hood construction
Production Lead Time— Approximately 2 weeks from pre-production sample approval
The Challenge
A well-established American craft brewery came to us looking for a manufacturing partner who could handle their branded apparel with the same care they put into their beer. They had worked with other suppliers before, but ran into recurring issues with fit and finish that needed to be solved:
Sizing built for Americans.
Their previous orders had fit problems — garments ran too slim for their team. They needed a roomy, boxy silhouette modeled after Russell Athletic sizing standards, with precise measurements from S through 3XL. Larger sizes needed to scale wider, not longer, with sleeve length fixed at 24” from L up.
Specific color and craft requirements.
Every detail was called out by number: body color #60 Dark Green with #125 Gold accents on the hoodie, #20 Gray with #38 Dark Gray contrast stitching on the sweatshirt. The client rejected standard plastisol screen printing for feeling too plastic-like and required water-based ink for a softer hand feel. Embroidery and print placement were specified down to the inch.
Multi-category seasonal orders.
Each order cycle covered 6 product categories — hoodies, sweatshirts, work shirts, flannels, printed shirts, and more — each with different fabrics, weights, and construction methods. The fall collection alone required 300GSM 100% cotton fleece for the hoodie and 280GSM 100% cotton French terry for the sweatshirt, with the client specifically requesting the exact same fabric quality as their previous order.
Cost-conscious without cutting corners.
When custom woven neck labels proved too costly at the required volume, the client worked with us to switch to 1.5” x 3” heat transfer printed labels — saving time and cost while maintaining a clean, branded finish.
The Sampling Process
Our approach was to send pre-production samples and color cards via UPS before committing to bulk production. This gave the client hands-on time with the actual garments, and gave us the feedback we needed to get everything right.
Fit and Sizing
We produced M, L, and XL test samples using available fabric so the client could evaluate fit before finalizing. After the first review, the client provided a full Russell Athletic size chart as the target. We adjusted sleeve length to 24” (fixed across L to 3XL), corrected cuff height from 4” to 3”, and ensured the overall silhouette stayed roomy and boxy. Our team also flagged a potential issue with armhole-to-sleeve proportions on 2XL/3XL sizes, which the client clarified should scale horizontally rather than vertically.
Print, Embroidery, and Color
The sweatshirt’s initial screen print had an overly plastic feel, so we switched to water-based ink at the client’s request — approved immediately for its softer hand. The print position was moved up 1 inch for better chest placement, and the logo’s center circle was corrected to show the garment’s body fabric color instead of white. On the hoodie, embroidery was repositioned 2 inches higher to sit centered on the chest. All accent colors were matched precisely: #125 Gold for the hood lining, drawstring, and embroidery on the hoodie; #38 Dark Gray contrast stitching on the sweatshirt.
Construction Refinements
The hoodie’s drawstring neck opening was reduced from 3 eyelet sets to 2, shortened by 2 inches for a cleaner look. Drawstring length was decreased from 54” to a uniform 32” across all sizes, based on our team’s suggestion. We also recommended shortening the V-neck panel to create more space for the upward-shifted logo. The client agreed to both adjustments.
Labels
The client initially wanted custom woven neck labels, but after learning about minimum order quantities, they opted for 1.5” x 3” heat transfer printed labels instead. This kept the branded look while reducing lead time and cost. The final label artwork was provided as a print-ready PDF.
Timeline
From first contact to confirmed delivery, the process took approximately 2 months, with the majority of time invested in getting the samples right:
Design Kickoff
Client sent design concepts for two key styles (hoodie and sweatshirt). We produced fit-test samples in M, L, and XL and shipped pre-production samples with color cards via UPS.
Fabric Confirmation
Client confirmed fabric specs: 300GSM 100% cotton fleece for the hoodie, 280GSM 100% cotton French terry for the sweatshirt, matching previous order quality.
Sample Review
Client reviewed samples and provided detailed feedback: color changes, print technique switch to water-based ink, sizing adjustments, embroidery repositioning, and construction modifications across both styles.
Final Adjustments
Updated size chart finalized. V-neck panel shortened, drawstring unified to 32" across all sizes, large-size proportions confirmed. Neck label changed from woven to heat transfer print.
Production
Fabric cut and bulk production completed within approximately 2 weeks of sample approval.
Delivery
Full order shipped via UPS. Client confirmed receipt of all boxes in good condition.
Quality Control and Shipping
Every garment was inspected against the approved pre-production sample before packing. During fabric cutting, our production team maximized material usage through efficient pattern layout, and the client was happy to accept the additional units. The complete order was packed and shipped via UPS, with tracking provided throughout.
This client has placed multiple seasonal orders with us, each time expanding their product range and trusting us with increasingly detailed customization. That repeat confidence is the result we value most.
Featured Products
Pullover Hoodie
Fabric: 300GSM 100% Cotton Fleece
Body Color: #60 Dark Green
Accent Details: #125 Gold hood lining, drawstring, embroidery
Branding: Custom embroidery (repositioned +2”)
Fit: Russell Athletic boxy silhouette
Neck Label: 1.5” x 3” heat transfer
Crewneck Sweatshirt
Fabric: 280GSM 100% Cotton French Terry
Body Color: #20 Gray
Accent Details: #38 Dark Gray contrast stitching
Branding: Water-based screen print (repositioned +1”)
Fit: Russell Athletic boxy silhouette
Neck Label: 1.5” x 3” heat transfer
Full Product Range Delivered
Pullover Hoodie
Fabric: 100% Cotton Fleece
Key Customization: Custom embroidery, lace-up hood, contrast hood lining
Crewneck Sweatshirt
Fabric: 100% Cotton French Terry
Key Customization: Water-based screen print, contrast stitching, woven label
Work Shirt
Fabric: Poly-Cotton Poplin
Key Customization: Custom design, custom sizing
Zip-Up Hoodie
Fabric: Poly-Cotton Fleece
Key Customization: Custom design, custom sizing
Flannel Shirt
Fabric: Poly-Cotton Flannel
Key Customization: Custom design, custom sizing
Printed Shirt
Fabric: 100% Cotton
Key Customization: DTG (direct-to-garment) printing
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