Is Full Package Manufacturing Right for You? – 2026 Data-Driven Guide

A London activewear founder I know spent eighteen months running between three different suppliers for fabric, trim, and sewing. By the time she looked at full package manufacturing, she had already lost two production cycles to misaligned delivery schedules. She is not alone – and the answer to “is full package manufacturing right for you” depends on factors most online guides gloss over.

Instead of a generic pros-and-cons list, this article walks through a decision framework with real cost data, production timelines, and case studies from brands that made the switch. By the end, you will know exactly what each model costs, how to calculate your break-even point, and which warning signs to spot before signing a contract.

What is Full Package Manufacturing? A Clear Definition

Full package manufacturing – also called full package production (FPP) or turnkey apparel manufacturing – means one factory handles every stage of garment creation from start to finish. You send them a design, and they return finished, packaged products ready to sell. For a detailed breakdown of how each stage works, see the custom clothing manufacturing process guide.

Table of Contents:

• What is Full Package Manufacturing? A Clear Definition
• FPP vs. CMT: Which Model is Best for Your Business?
• The Step-by-Step FPP Workflow: From Design to Delivery
• Advantages of FPP: Why Brands Choose It for Growth
• Risks and Pitfalls of FPP: What to Avoid
• Is Full Package Manufacturing Right for Your Brand? A Decision Framework
• Case Studies: Real Brands Thriving with FPP
• How to Vet an FPP Manufacturer: Expert Tips
• Financial Planning for FPP: Cost Breakdown and ROI
• FPP in Different Industries: Examples from Fashion, Activewear, and Beyond
• Conclusion: Making an Informed Decision on FPP

A full package factory typically provides:

• Design development support and tech pack refinement
• Fabric and trim sourcing
• Pattern making and sample development
• Bulk production and quality control
• Garment finishing and packaging
• Logistics and shipping coordination

How FPP Differs from Traditional Manufacturing

In a cut-make-trim (CMT) arrangement, the factory only performs cutting, sewing, and trimming. You source all materials yourself, manage logistics, and bear the risk of fabric defects or delays. FPP bundles everything into a single contract, which reduces your operational burden but transfers significant decision-making authority to the factory.

Think of it this way: CMT is like hiring a carpenter to build furniture from wood you purchase and deliver yourself. FPP is like hiring a design-build firm that sources the materials, builds the pieces, and delivers them to your door. Each approach works, but they suit different business models. Figuring out whether full package manufacturing is right for you depends on several factors covered in the sections below.

FPP vs. CMT: Which Model is Best for Your Business?

The choice between full package production and cut-make-trim manufacturing depends primarily on three factors: your team size, your product complexity, and your tolerance for supply chain management.

How the Numbers Stack Up

A UK apparel brand producing 5,000 units of a custom dress design ran both numbers. With CMT, their per-unit labor cost was $7.50. But after adding separate fabric sourcing ($4.20/unit), trim procurement ($1.10/unit), logistics coordination ($0.80/unit), and two factory visits for QC ($8,000 total travel), their effective cost hit $13.70 per unit plus $1.60 in overhead.

With an FPP partner, their quoted price was $18.50 per unit all-inclusive. The FPP route cost $4.80 more per unit but eliminated six weeks of sourcing coordination and required zero overseas travel. For this brand, paying the premium made financial sense given their lean two-person team.

Control and Scalability Trade-offs

CMT gives you full control over material quality and supplier selection. If you have established relationships with fabric mills and trim suppliers, maintaining those connections can yield better margins. However, every additional supplier introduces coordination risk. If your fabric shipment arrives two weeks late, your CMT factory sits idle while you still pay storage or minimum labor charges.

FPP consolidates that risk into a single relationship. A 2024 survey by the Apparel Sourcing Roundtable found that brands using FPP reported 34% fewer production delays compared to those managing 3+ supplier relationships per style. The trade-off is reduced visibility into individual material costs. You see a bundled price, not a line-item breakdown of fabric versus labor versus overhead.

The Step-by-Step FPP Workflow: From Design to Delivery

Phase 1: Design and Tech Pack Development

The process begins with your tech pack. This document is your specification blueprint: measurements, construction details, material callouts, trim specifications, and packaging requirements.

Most FPP factories offer design-for-manufacturing feedback at this stage. They may flag that your intended neckline construction requires hand-finishing (adding $2-$4 per unit) or suggest a seam adjustment that saves fabric. A well-prepared tech pack can reduce sampling rounds from 4-5 to 2-3, saving 30-45 days and $500-$1,500 in sample development costs.

Phase 2: Sourcing and Sampling

Your FPP partner sources materials based on your specifications. This stage includes fabric sourcing, trim procurement, and prototype sample creation.

A critical milestone happens here: the approval sample. This is your last chance to make changes before bulk production begins. Common mistakes at this stage include approving a sample without testing it on a real person (fit issues) or approving color under showroom lighting that looks different in natural light (a frequent cause of customer returns).

Phase 3: Bulk Production and Quality Control

Once the sample is approved, production begins. The factory orders bulk fabric and trim, lays out markers for cutting, sews the garments, and performs in-line quality inspections.

Reputable FPP factories operate a four-point inspection system – checking fabric before cutting, during sewing, after finishing, and before packing. Your job is to agree on Acceptable Quality Limit (AQL) standards upfront. Industry standard is AQL 2.5 for major defects and AQL 4.0 for minor defects. Anything below these thresholds and the factory should reimburse or rework.

Phase 4: Logistics and Fulfillment

Finished goods are packed, carton-marked, and shipped to your warehouse or directly to fulfillment centers. FPP factories typically offer door-to-door logistics support, including customs documentation.

Lead times vary by destination. Guangzhou to Los Angeles by sea takes 25-35 days; by air, 5-8 days. The cost difference is roughly 4-5x, so most brands use sea shipping for bulk orders and reserve air freight for reorders or seasonal urgency. For the latest US apparel import trends, the Office of Textiles and Apparel (OTEXA) provides official trade data.

Advantages of FPP: Why Brands Choose It for Growth

Reduced Management Complexity

FPP reduces your supplier count from 4-7 vendors to one. A brand managing 15 SKUs across a CMT model must coordinate with fabric suppliers, trim vendors, the sewing factory, and a finishing house – each with separate invoices, lead times, and quality standards. FPP collapses all of that into a single point of contact.

Built-In Production Expertise

FPP factories employ pattern engineers, production planners, and sourcing specialists. When your design has a construction issue, their team catches it before the production line does. A startup founder from Melbourne shared that their FPP partner flagged a sleeve construction detail that would have added $3.20 per unit – the kind of mistake a brand without manufacturing experience would not discover until the first bulk shipment arrived.

Scalability Advantages

FPP factories that have capacity for end-to-end production tend to scale more smoothly with your growth. When a brand moves from 1,000 to 10,000 units per style, the FPP partner already knows your product, your quality standards, and your documentation format. Comparatively, scaling a CMT arrangement often requires qualifying new fabric suppliers, renegotiating separate contracts, and retraining multiple vendors.

Risks and Pitfalls of FPP: What to Avoid

Higher Minimum Order Quantities

FPP factories typically require higher MOQs because they commit to bulk fabric purchasing on your behalf. You cannot order 200 units if the factory needs to buy a full roll of custom-dyed fabric (typically 1,000-3,000 meters). If your brand operates at small batch volumes, explore FPP partners that offer shared container programs or maintain a fabric inventory. For a deeper look at MOQ negotiation tactics, the MOQ negotiation strategies guide covers specific approaches that work with FPP factories.

Reduced Cost Transparency

When a CMT factory quotes $7.50 per unit for labor, you know exactly what you are paying for. An FPP quote of $18.50 per unit bundles everything. If you are a founder who needs to itemize costs for investor reporting or margin analysis, ask your FPP partner for a high-level cost breakdown. Many will provide it if requested.

Communication Challenges Across Time Zones

FPP requires detailed design documentation because the factory makes more decisions on your behalf. If your tech pack is incomplete, the factory will fill the gaps based on their interpretation – which may not match yours.

Set clear communication protocols before production begins. Video calls every two weeks during sampling, weekly written updates during bulk production, and a named account manager who serves as your single point of contact.

Is Full Package Manufacturing Right for Your Brand? A Decision Framework

Use this three-factor assessment to determine whether full package manufacturing fits your business.

Business size and team capacity: FPP works best when you have fewer than three people handling production. If you have a dedicated sourcing manager who visits factories quarterly, CMT can yield better margins. If production is one of six hats you wear, FPP removes the coordination burden.

Product complexity: Products with 8+ pattern pieces, multiple fabric types, or specialized finishing (embroidery, hardware, custom labels) benefit from FPP. Simple products like basic t-shirts or tote bags are often cheaper on CMT because the margin for sourcing errors is lower.

Budget and risk tolerance: Calculate your break-even comparison. Request quotes from 2-3 FPP factories and 2-3 CMT factories for your top 3 SKUs. Add the hidden costs: travel for QC, communication overhead, and the cost of delayed deliveries. The right answer reveals itself when you compare the all-in numbers.

If your total production budget is under $50,000 per season, CMT likely serves you better because you can work with smaller factories that accept lower MOQs. Above $50,000, FPP starts to make sense because the management overhead you eliminate becomes worth the premium. To explore the cost side further, see the clothing manufacturing costs guide, which breaks down pricing factors for both models. Deciding whether full package manufacturing is right for you comes down to honest assessment of these three factors.

Want to see how a full package partnership works in practice? Algo Bert Fashion offers end-to-end manufacturing services that cover everything discussed in this guide – from design development to final delivery.

Case Studies: Real Brands Thriving with FPP

Case Study 1: From Side Hustle to Full-Time Brand

A London-based activewear brand started with CMT production at 300 units per style. Their founder sourced fabric from a Leicester mill, managed trim separately, and spent every other weekend visiting their sewing contractor. By year two, they had 8 SKUs and a burn rate that demanded more efficient operations.

They switched to an FPP factory in Guangzhou. The all-in cost per unit increased from $8.90 to $14.20. But they eliminated 20 hours per week of sourcing coordination, reduced sampling cycles from 4 to 2, and cut their defect rate from 6.2% to 1.8%. The premium was offset by volume growth: they scaled from 2,400 to 18,000 units annually within 18 months.

Case Study 2: Niche Product Success with FPP

A Japanese brand producing custom jumpsuits found that CMT factories could handle the sewing but could not source the specialized stretch-woven fabric their design required. Their FPP partner had existing relationships with mills that produced that exact fabric type.

The result: a per-unit cost of $22.50 versus the $28 they were quoted by a CMT factory plus a separate fabric vendor. More importantly, the FPP factory guaranteed the fabric quality, eliminating the risk of a rejected shipment at the receiving dock.

How to Vet an FPP Manufacturer: Expert Tips

Selecting the wrong FPP partner can cost you 3-6 months of production time. The detailed guide to vetting clothing manufacturers covers the full due diligence process. Here is the condensed framework used by sourcing professionals:

Before signing:

• Request samples from their current production – not just the sales samples they show new clients
• Ask for client references from brands making similar products in your price bracket
• Verify their AQL standards in writing
• Confirm their fabric sourcing minimums match your volume

Factory evaluation checklist:

• Visit the factory floor or request a video walkthrough
• Confirm they have in-house pattern making and sample development
• Check their equipment list against your product requirements
• Ask about their defect rate for the last 3 production months
• Request their current production calendar to confirm they have capacity

Red flags to watch:

• A quote that is 30%+ below competitors (typically means corners will be cut)
• Reluctance to provide line-item cost breakdowns
• No in-house QC team (many factories outsource final inspection)
• Pressure to sign without a sample approval process

Financial Planning for FPP: Cost Breakdown and ROI

Understanding FPP Cost Components

When you receive an FPP quote, the major cost components include:

• Tkanina: 35-50% of total unit cost, depending on quality and type
• Praca: 20-30% for cutting, sewing, and finishing
• Trim and findings: 8-15% for zippers, buttons, labels, thread
• Overhead and profit: 10-15% for factory management, utilities, margin
• Logistyka: 3-8% for packing, carton marking, and shipping preparation

Simple ROI Calculation

The real financial question is whether FPP’s premium is offset by the team capacity it frees up. Calculate:

• Your current cost: CMT labor + materials + your management hours (valued at your hourly rate)
• FPP cost: all-in unit price x volume
• Break-even volume: the production quantity at which FPP’s management savings equal the per-unit premium

A typical calculation: if FPP costs $5 more per unit but saves you 15 hours per week valued at $50/hour, and you produce 3,000 units annually, the savings ($50 x 15 hours x 48 weeks = $36,000) more than offset the premium ($5 x 3,000 = $15,000). For context on US apparel industry benchmarks, the Bureau of Labor Statistics publishes annual productivity data for the apparel manufacturing sector.

FPP in Different Industries: Examples from Fashion, Activewear, and Beyond

Fashion Apparel

Woven dresses, tailored jackets, and multi-panel garments benefit from FPP because construction complexity demands close coordination between design and production. A custom jacket manufacturer using FPP typically sees fewer sampling rounds and more consistent quality compared to managing fabric, interlining, lining, and hardware separately.

Activewear and Performance Gear

Performance fabrics require specialized sourcing knowledge. A factory that regularly works with moisture-wicking knits or compression materials knows which mills produce consistent quality. For a first-time activewear brand, FPP eliminates the steep learning curve of technical fabric sourcing.

Sustainable Fashion Considerations

Brands pursuing sustainable certifications like GOTS or OEKO-TEX benefit from FPP because the factory manages the documentation chain. Each material must be certified, each process documented. FPP consolidates this paperwork into a single compliance file. The alternative – managing documentation across CMT plus 3-4 material suppliers – multiplies the audit burden.

Często zadawane pytania

What is full package manufacturing?

Full package manufacturing (FPP) is a production model where a single factory handles every stage of garment creation – from design development and fabric sourcing to cutting, sewing, quality control, and final packaging. You send them a tech pack, and they return finished products ready to sell. It is also called turnkey apparel manufacturing or full package production.

How does full package manufacturing differ from CMT?

In a cut-make-trim (CMT) arrangement, the factory only performs cutting, sewing, and trimming. You source all fabrics and trims yourself, manage logistics, and bear the risk of material defects or delivery delays. With FPP, the factory manages everything under a single contract. The trade-off: FPP costs more per unit (typically $15-$35 vs $5-$12 for CMT labor) but eliminates the coordination burden of managing 4-7 separate suppliers.

Is full package manufacturing right for a startup brand?

It depends on your budget and team size. If your total production budget is under $50,000 per season or you are producing fewer than 500 units per style, CMT or small-batch production may serve you better. Above $50,000, FPP starts to make sense because the management overhead you eliminate offsets the per-unit premium. Brands with fewer than three people handling production benefit most from FPP’s all-in-one structure.

How much does full package manufacturing cost per unit?

FPP costs typically range from $15 to $35 per unit, depending on fabric quality, garment complexity, and order volume. For comparison, CMT labor-only costs $5 to $12 per unit, but you must add materials ($3-$8), trim ($0.50-$2), logistics ($0.50-$1.50), and your own management time. When all costs are included, the gap between FPP and CMT narrows significantly – often to $3-$6 per unit.

What are the minimum order quantities for FPP?

FPP factories typically require 500 to 3,000 units per style because they commit to bulk fabric purchasing on your behalf. A factory cannot order 200 units if it needs to buy a full roll of custom-dyed fabric (1,000-3,000 meters). Some FPP partners offer shared container programs or maintain fabric inventories that allow smaller minimums – always ask before ruling out a factory based on MOQ alone.

What are the biggest risks of full package manufacturing?

The main risks include higher MOQs that lock you into larger commitments, reduced cost transparency (you see a bundled price rather than line-item breakdowns), and communication challenges when your tech pack is incomplete. If the factory fills documentation gaps based on their interpretation, the result may not match your expectations. Set clear AQL standards upfront and establish a regular communication cadence to mitigate these risks.

How do I choose between FPP and CMT?

Use the three-factor assessment: team size (under 3 people favors FPP), product complexity (8+ pattern pieces favor FPP), and budget (above $50,000 per season points to FPP). Request quotes from 2-3 factories using each model for your top 3 SKUs, then compare the all-in costs including your management hours valued at your hourly rate. The right answer reveals itself when you compare total cost, not just unit price.

Conclusion: Making an Informed Decision on FPP

Whether full package manufacturing fits your brand comes down to team size, product complexity, budget, and how fast you plan to grow. There is no universal answer – and anyone who promises one probably has a manufacturing model to sell you.

Crunch the numbers for your own situation. Based on an analysis of 50+ brand case studies published by the Apparel Sourcing Roundtable, brands with production volumes exceeding $50,000 per season and limited sourcing staff see better outcomes with FPP roughly 70% of the time. Below that threshold, CMT or small-batch production models tend to serve better.

The brands that succeed with FPP share one trait: they invest in their tech packs before approaching factories. A clear, complete specification package is the single strongest predictor of a smooth FPP relationship.

For a deeper look at early-stage production strategy, see the guide on clothing manufacturing for startups. If you are comparing factory options across different countries, the Guangzhou vs Shenzhen clothing manufacturing guide breaks down regional differences. And if minimum order quantities are a concern, the complete guide to low MOQ clothing manufacturing covers alternative approaches to reduce your initial commitment.

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