How to order quarter zips for a 60-person company
Sixty people is the size where a quarter zip order stops being casual. Sizes spread out, some staff want a women's cut, and the tier math starts to matter. Here is the plan Battle Born Clothing walks buyers through.
Step 1: pick one style, or one pair
Pick a single unisex style for simplicity, usually the Port Authority F218 fleece. If a meaningful share of the team wants a women's cut, add a matched pair: Independent EXP20PQ and EXP15WPQ for performance, or F218 plus the IND280MOCK mock neck for fleece. Keep it to two styles; every added style is priced at its own tier and makes the size list harder.
Step 2: collect sizes the easy way
Send staff a one-line form: name, unisex or women's, size. Give them the supplier's size chart (we send it with the quote). Expect this distribution on a typical 60-person adult order:
| Size | Share | Pieces |
|---|---|---|
| S | 10% | 6 |
| M | 25% | 15 |
| L | 30% | 18 |
| XL | 20% | 12 |
| 2XL | 10% | 6 |
| 3XL | 5% | 3 |
2XL and up carry a supplier upcharge of roughly $1 to $7 per piece depending on size; it shows on your quote.
Step 3: order extras
Add 3 to 5 percent in the most common sizes (M, L, XL) for new hires and the person who skipped the form. On 60 that is 2 to 3 pieces. If you are near a tier line, round up to it: 72 pieces costs the same per piece as 48, and 96 drops to $26.57.
Step 4: the math
| Line | Math | Total |
|---|---|---|
| 60 F218 at 48-71 tier | 60 × $27.07 | $1,624.20 |
| Digitizing, one design | one time | $18.99 |
| Total before freight and 2XL+ upcharges | $1,643.19 |
Swap 20 of those for a women's EXP15WPQ and you have 40 F218 at the 24-47 tier ($27.57) plus 20 EXP15WPQ quoted per job at its own tier. On matched programs ask us; we will often combine the count into one tier.
Step 5: artwork and proof
Send the logo as vector (AI, EPS, PDF, SVG) or 300 dpi PNG, with brand colors. We digitize ($18.99, standard 2-day) and send a digital proof showing size, placement and thread colors. Approve it and the 28-day clock starts.
Step 6: timing
Quote same business day. Proof a few days after art. Production 28 days from approval. Freight 1 to 5 days. For a holiday delivery, approve by early November. Read the gift-season timeline.
Step 7: delivery
We fold and bag each piece and label by size. One box to one address is standard. Splitting across offices is fine; give us the breakdown. Freight is billed at cost.
Reorders
Your digitized file stays on our machines. A reorder of 8 pieces for new hires is quoted per job at blank plus embroidery, no new setup. Thread colors and placement match the first run.
Questions
Should we let people choose their own color?
You can, but each color is still the same style so it does not change the tier. Keep it to two colors or sorting gets messy.
What if someone's size is wrong after delivery?
Embroidered garments cannot be returned to the supplier. That is why we suggest 3 to 5 percent extras in common sizes.