The first run is only the beginning. Reorder planning is what keeps a good product alive long enough to become a real business.
A reorder system should start before the first batch ships. Keep fabric references, trims, dye lots, and approval records organized so that a second run can move faster than the first.
The biggest risk in restocks is not only stockout. It is inconsistency, where the new production looks close but not identical enough to satisfy returning customers.
Reserve extra raw material whenever possible if the product is a likely bestseller. Small buffers in fabric and packaging can save weeks later.
Track sell-through by size and color early. Reorder decisions should be based on actual demand patterns, not just intuition.
Incoterms Explained: Who Pays for What Between Factory and Doorstep
Incoterms (International Commercial Terms) define the division of cost, risk, and responsibility between seller and buyer from the factory gate to the final delivery point. The three most important for apparel importers are FOB, CIF, and DDP. FOB (Free on Board) means the seller's responsibility ends when goods are loaded onto the vessel at the origin port — all costs and risks after that are the buyer's. CIF (Cost, Insurance, Freight) includes freight and marine insurance to the destination port but excludes customs clearance. DDP (Delivered Duty Paid) means the seller handles everything including import customs — the buyer receives goods at their warehouse with zero logistics complexity.
Most Bangladesh factories quote FOB Chittagong (or FOB Dhaka for air). This is the cleanest baseline for cost comparison: you can source freight forwarders independently and control that line of your landed cost budget. CIF is convenient but can obscure freight margins — some suppliers inflate CIF rates as a secondary revenue stream. DDP suits brands scaling beyond operational bandwidth for import logistics, but typically costs 10–15% more than self-managed freight.
Sea vs. Air Freight: The Apparel Importer's Cost-Time Trade-Off
Sea freight from Chittagong to US East Coast ports (New York, Savannah, Charleston) takes approximately 25–30 days in transit, with 3–7 additional days for customs clearance. West Coast ports (Los Angeles, Long Beach) are 21–25 days. The cost runs $1.50–$2.50 per kilogram for a standard FCL container, depending on route and market conditions. A 500-unit hoodie order weighing approximately 400 kg would cost $600–$1,000 in sea freight — roughly $1.20–$2.00 per unit landed on the freight line.
Air freight runs 3–5 business days door-to-door and costs $5–$8 per kilogram — three to five times more expensive than sea on a per-unit basis. For that same 400 kg hoodie order, air freight runs $2,000–$3,200, adding $4–$6.40 per unit to your landed cost. Air freight is economically justified for fashion-sensitive drops where timing is critical, urgent bestseller restocks mid-season, or bridging a stock gap caused by delayed sea shipment — never for planned production cycles where sea timing is fully predictable.
Expert Tip Build your production calendar backward from your target launch or in-store date. Add: 3 days for export document processing, 25–30 days sea transit to US East Coast, 5 days customs clearance, 2 days domestic trucking to your warehouse. That is 35–40 days from factory production completion to warehouse arrival. Most brands underestimate this by two full weeks and end up paying air freight premiums that wipe out their margin on the order.
Frequently Asked Questions
What is a freight forwarder and do I need one?
A freight forwarder books container space with shipping lines, prepares export documentation, and coordinates delivery at the destination port. For sea freight, yes — you need one. They charge $150–$350 in handling fees plus the shipping line's freight rate. For air shipments, your courier or airline handles forwarding. Choosing a forwarder with Bangladesh experience saves time and prevents documentation errors at origin.
How can I minimize import duties on Bangladesh-origin garments?
Duties are set by your country's tariff schedule and the garment's HS code — you cannot negotiate them away. What you can do: ensure the factory provides a correct Certificate of Origin (Form A for EU GSP+), classify goods under the correct HS code (misclassification triggers customs audits and penalties), and for EU imports, confirm your factory's GSP eligibility, which brings the duty rate to 0%.
What is the difference between LCL and FCL shipping?
FCL (Full Container Load) means your order fills a 20-foot or 40-foot container exclusively. LCL (Less than Container Load) means your goods share container space with other importers and you pay only for your CBM (cubic meter) volume. LCL is typically more cost-effective below 10 CBM; FCL becomes cheaper and faster above 10–15 CBM because there is no consolidation delay at the origin warehouse.
Key Takeaways
- Quote comparison should always use FOB Chittagong as the baseline — it separates the factory price from freight costs you can control.
- Allow 35–40 days from factory production completion to US warehouse arrival when planning sea freight timelines.
- Air freight costs 3–5× more per kilogram than sea — budget it only for urgent restocks, never for planned seasonal production.
- Build your production and shipping calendar backward from your target launch date, not forward from order placement.
- Correct Certificate of Origin documentation unlocks GSP duty preferences in the EU — verify it before every shipment.
NH
Written by
Nasrin Haq
Member of the Essential Apparel production team, sharing first-hand insight from our Dhaka factory floor.
