Most brands guess their margins. They ask factories for a price list, but manufacturing isn’t a menu—it’s math. This case study is a practical addendum to our comprehensive apparel manufacturing Guide, releasing The Synerg’s internal pricing data for February 2026.
We will look at two scenarios based on real production data from our Tirupur facility:
- Scenario A: A Standard 300 GSM Hoodie (The Baseline).
- Scenario B: A Heavyweight 500 GSM Hoodie (The “Fear of God” Trend).
1. The Baseline: $6.60 Standard Hoodie (Real Invoice)
This breakdown is based on a redacted invoice from a February 2026 Hoodie order manufactured for Spainish brand. The garment is a 100% Cotton Loop Knit (French Terry) at 280-300 GSM.
| Cost Component | Spec / Metric | Cost (USD) |
|---|---|---|
| Fabric Cost | Rate: ₹550/kg (730g cons.) | $4.61 |
| CMT (Labor) | Cut, Make, Trim | $0.61 |
| Printing | Standard Chest Print | $0.28 |
| Accessories | Labels, Drawstrings | $0.17 |
| Factory Margin | Overheads & Profit | $0.93 |
| FINAL FOB PRICE | Ready to Ship | $6.60 |
💡 The Synerg Insight: It’s All in the Fabric
Notice that Fabric (Raw Material) is 70% of the cost ($4.61). The stitching (CMT) is only $0.61. This proves that if you want a cheaper hoodie, you can’t just “negotiate harder” with the factory—you have to lower the fabric weight. The math doesn’t lie.
2. The Heavyweight Trend: 500 GSM Costing
Founders often assume a 500 GSM “Yeezy Style” hoodie will cost just a little bit more than a standard one. The reality is a massive price jump due to consumption and machine speed.
*Note: For brands seeking a middle ground, a 350 GSM upgrade typically adds only ~$0.40 to the base fabric cost, making it a budget-friendly alternative.
| Component | Standard (300 GSM) | Heavyweight (500 GSM) |
|---|---|---|
| Fabric Consumption | 730 grams | 1.2 kg (Boxy Fit Waste) |
| Fabric Cost | $4.61 | $8.50 |
| CMT (Labor) | $0.61 | $1.10 (Slow Stitching) |
| ESTIMATED FOB | $6.60 | ~$12.50 |
3. The Logistics Reality: Sea vs. Air Freight
A common question we receive is regarding the impact of the Red Sea crisis on shipping rates. Below are the February 2026 benchmarks for 500 units.
- Air Freight (5-7 Days): ~$5.20 per unit (Too expensive for wholesale).
- Sea Freight (40 Days): ~$0.85 per unit (Recommended).
The “Hidden Costs” Calculator
Finally, don’t forget the fees that don’t appear on the garment tag:
- Lab Testing: ~$27.00 per batch for shrinkage/GSM checks.
- Import Duty & VAT: If applicable for your country for importing hoodies from India.
Frequently Asked Questions
Is $6.50 a fair FOB price for a 100% cotton french terry hoodie?
Yes. Based on actual February 2026 production data from Tirupur, the manufacturing cost for a standard 300 GSM Loop Knit (French Terry) hoodie is approximately $6.60. This includes fabric, labor (CMT), and factory margins.
How much does it cost to manufacture a 500 GSM heavyweight hoodie?
A 500 GSM heavyweight hoodie costs approximately $12.50 FOB in 2026. This is significantly higher than standard hoodies because fabric consumption nearly doubles and knitting machines must run slower.
What is the shipping cost per hoodie from India to the UK/USA?
Due to the Red Sea crisis, shipping rates have diverged. As of February 2026, Sea Freight (LCL) costs approximately $0.85 per unit (40-45 days transit), while Air Freight is ~$5.20 per unit.
What are the hidden costs in clothing manufacturing?
Brands must budget for Lab Testing (~$27 per batch) and bank charges for international wire transfers or Letters of Credit.
Need a Precise DDP Quote?
Stop guessing your landed costs. Get a guaranteed DDP (Delivered Duty Paid) quote for your 2026 collection.
Karthik Shan
CEO of Synerg. With 20+ years in Tirupur manufacturing, Karthik helps global brands navigate the complexities of pricing, sourcing, and logistics in the Indian apparel sector.