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• December 20, 2025

Cost Breakdown for Manufacturing a T-Shirt in Tirupur: Complete Production Guide

Cost breakdown manufacturing t-shirt Tirupur is essential for understanding production expenses. Manufacturing a t-shirt in Tirupur involves multiple cost components. Understanding this cost breakdown helps buyers negotiate better prices and manufacturers optimize production. Here is a complete guide to t-shirt manufacturing costs in Tirupur region.

Raw Material Costs in T-Shirt Manufacturing Tirupur

Fabric Cost: Fabric is the largest expense. Quality cotton costs Rs 200-300 per kg. Blended fabrics Rs 150-250 per kg. One t-shirt uses approximately 200-250 grams of fabric. Fabric cost per shirt: Rs 40-75.

Thread Cost: Thread accounts for minimal cost. High-quality thread Rs 2-5 per shirt. Standard thread Rs 1-3 per shirt. Specialized threads cost more.

Other Materials: Labels, tags, buttons Rs 5-15 per shirt. Packaging materials Rs 3-8 per shirt. Total material cost per shirt ranges Rs 50-100.

Labor Costs

Cutting: Skilled cutters earn Rs 15,000-25,000 per month. They cut 100-150 shirts per day. Cost per shirt: Rs 3-5.

Sewing: Sewing operators earn Rs 12,000-20,000 per month. Experienced operators produce 40-60 shirts daily. Cost per shirt: Rs 4-8.

Finishing: Finishing workers earn Rs 10,000-18,000 monthly. They finish 80-120 shirts daily. Cost per shirt: Rs 2-4.

Quality Control: QC staff earns Rs 12,000-18,000. They inspect 150-200 shirts daily. Cost per shirt: Rs 1-2.

Total labor cost per shirt: Rs 10-20.

Factory Overhead Costs

Electricity: Average Rs 15,000-30,000 per month per sewing unit. For 2000 shirts monthly: Rs 7-15 per shirt.

Water: Rs 3,000-8,000 monthly. For 2000 shirts: Rs 1.50-4 per shirt.

Rent: Ranges Rs 20,000-50,000 monthly. For 2000 shirts: Rs 10-25 per shirt.

Maintenance: Machinery maintenance Rs 5,000-10,000 monthly. Cost per shirt: Rs 2.50-5.

Other overhead (admin, waste): Rs 3,000-8,000 monthly. Cost per shirt: Rs 1.50-4.

Total overhead per shirt: Rs 22-53.

Production Efficiency Factors

Batch Size Impact: Smaller batches (500 shirts): Higher per-unit cost Rs 100-120. Medium batches (2000 shirts): Rs 80-100 per shirt. Large batches (5000+ shirts): Rs 70-85 per shirt.

Complexity: Plain t-shirts: Lowest cost. Printed designs: Add Rs 10-25. Embroidered designs: Add Rs 25-50. Multiple colors: Add Rs 5-15.

Quality Standards: Basic quality: Lower cost. International standards (ISO): Add Rs 5-10. Certified (GOTS): Add Rs 15-25.

Seasonal Variations

Peak Season (Oct-Dec): Prices increase 5-10% due to high demand. Off-season (Jun-Aug): Discounts 10-15% available. Holiday season: Rush charges 15-25%.

Complete Cost Breakdown Example (1000 Unit Order)

Raw Materials: Rs 60-75 per shirt. Total: Rs 60,000-75,000
Labor Costs: Rs 15-20 per shirt. Total: Rs 15,000-20,000
Factory Overhead: Rs 30-50 per shirt. Total: Rs 30,000-50,000
Quality Testing: Rs 5-10 per shirt. Total: Rs 5,000-10,000
Packaging: Rs 5-8 per shirt. Total: Rs 5,000-8,000

Total Production Cost: Rs 115-163 per shirt
Manufacturer Margin (15-25%): Rs 17-41 per shirt
Final Price to Buyer: Rs 132-204 per shirt

Cost Reduction Strategies

Increase Order Quantity: Negotiate volume discounts. Suppliers offer 5-10% discount for 5000+ units. Even better rates for 10,000+ units.

Long-term Partnerships: Commitment to regular orders reduces costs 10-15%. Stable orders allow better planning and efficiency.

Simplify Design: Reduce colors and embellishments. Solid color shirts cost less than printed. Fewer stitching lines reduce labor.

Flexible Timeline: Urgent orders have 20-30% surcharge. Standard timeline (45-60 days) offers best rates. Off-season production saves 10-15%.

Vertical Integration: Some suppliers handle fabric sourcing. Reduces intermediaries and costs. Direct dyeing units cut costs 8-12%.

Frequently Asked Questions

What is the minimum order quantity? Most manufacturers: 500-1000 pieces. Some accept 100+ pieces with premium pricing. MOQ reduces per-unit cost significantly.

How long does production take? Standard: 45-60 days. Rush orders: 20-30 days (additional cost). Lead time affects overall pricing.

Can prices be negotiated? Yes, based on volume and commitment. Long-term orders get better rates. Payment terms also affect pricing.

What affects price most? Fabric quality (40-50% of cost). Quantity (volume discounts). Design complexity (10-20% variation). Quality standards.

Are there hidden costs? Ensure clarity on what’s included. Confirm: fabric cost, labor, packaging, quality checks. Clarify shipping responsibility.

Pros and Cons of Tirupur Manufacturing

Pros:
Lowest manufacturing costs globally
Experienced and skilled workforce
Flexible order quantities
Quick production timelines
Quality meets international standards

Cons:
Minimum order quantities
Communication barriers (language)
Long shipping times
Currency fluctuations
Quality inconsistency between suppliers

Conclusion

Cost breakdown for t-shirt manufacturing in Tirupur shows raw materials as the largest component. Labor costs remain competitive compared to developed countries. Understanding these costs helps negotiate better prices. Bulk orders significantly reduce per-unit costs. Choose experienced suppliers for consistent quality and competitive pricing in Tirupur.