Knitwear capacity: what 12M pieces a season looks like
Scaling knitwear production to 12 million pieces a season requires more than factory space. Here is how we approach capacity planning, factory alignment and risk distribution across our knit partner network.
Knitwear is Bangladesh's largest export category by volume, accounting for nearly 60% of total RMG output. The country's knit factories range from small 200-machine operations to vertically integrated giants running 3,000+ circular knitting machines with in-house dyeing, cutting and finishing.
For a 12M piece season across multiple styles and constructions, we typically distribute across three to five factories. Single-factory concentration creates schedule risk — a machine breakdown, a power disruption or a compliance issue can cascade into a missed shipment window.
Our capacity allocation model starts with style complexity. Basic single-jersey tees and polos go to high-volume, mid-tier factories where efficiency is paramount. Engineered stripes, jacquards, full-fashion knitwear and heavy fleece are allocated to specialist mills with the right equipment and pattern-making capability.
Lead times for knit programmes: 90–110 days from approved sample to loading, assuming fabric is in-stock at the mill. Custom yarn colours add 15–20 days. Rush programmes can be accommodated at select factories for an FOB premium of 4–8%.