Custom Scrubs in Bulk: Fabric, MOQ, and Cost for US Clinics
Custom scrubs in bulk run about $9 to $22 per set at the factory, before decoration and freight. Branding stock scrub bodies with embroidery usually starts near 50 pieces per style, while a fully custom fabric run needs roughly 300 to 500 pieces per color. Plan 5 to 7 sets for each full-time clinical worker, and lock a single dye lot so reorders match.
Dental groups, urgent care networks, veterinary clinics, med spas, and physical therapy practices in the US buy scrubs the same way: a branded, matching look across the team, sizes that fit real bodies, and a color that still matches when a new hire starts six months later. This guide covers the fabric, minimum order quantity, decoration, sizing, cost, and US compliance details a buyer needs before sending a scrub program to production.
What does it cost to order custom scrubs in bulk?
Scrub cost depends on the fabric weight, the blend, the decoration, and the run size. The single biggest lever is how custom the garment is. A stock scrub body with your embroidered logo is far cheaper to start than a run cut from your own dyed fabric. The table below shows typical factory-direct set prices (top plus pant) at common quantities, before decoration, freight, and duty.
| Order size (sets) | Poly-cotton set | Performance stretch set | Antimicrobial set |
|---|---|---|---|
| 50 to 99 | $14 to $18 | $18 to $24 | $20 to $26 |
| 100 to 299 | $12 to $15 | $15 to $20 | $17 to $22 |
| 300 to 999 | $10 to $13 | $13 to $17 | $15 to $19 |
| 1,000+ | $9 to $11 | $11 to $14 | $13 to $16 |
Two cost notes buyers miss. First, the biggest per-piece drop happens between 50 and 300 sets, because the fixed setup for cutting and sewing spreads across more garments. After that the curve flattens. Second, the number that hits your budget is landed cost, which is the factory price plus embroidery, freight, and any duty. Ask for the quote broken out that way rather than a single blended figure. For how those numbers are built, see our explainer on MOQ, pricing, and lead times.
What fabric should you choose for scrubs?
Fabric is the decision that determines comfort on a 12-hour shift, how the scrub survives industrial laundry, and whether it holds color after a hundred washes. Match the fabric to the department, not to the lowest price. The specs below are the four blends we run most for US clinical work, with weight in grams per square meter (GSM) and wash durability measured on repeated hot-water cycles.
| Fabric | Composition | Weight | Wash durability | Best for |
|---|---|---|---|---|
| Poly-cotton | 55% polyester / 45% cotton | 150 to 165 GSM | 70+ cycles | General wards, outpatient, admin |
| Performance stretch | 90% polyester / 10% spandex | 175 to 195 GSM | 80+ cycles | OR, ICU, ER, long shifts |
| Silver-ion antimicrobial | 95% polyester / 5% silver-ion fiber | 160 to 180 GSM | 75+ cycles | Surgical, dental, infection-control priority |
| Premium blend | Polyester / rayon / spandex | 185 to 205 GSM | 100+ cycles | Private-label and executive medical wear |
A common mistake is buying a light 145 GSM top to cut cost, then finding it goes sheer under clinic lighting and pills within a season. For most US clinics a poly-cotton around 155 GSM is the safe general-purpose pick, while high-motion departments do better in a 175 GSM-plus stretch. Ask any factory for the actual test data, which is fabric composition by percentage, GSM, and colorfastness rating, rather than the phrase "medical-grade fabric" with nothing behind it.
What is the MOQ for custom scrubs?
Minimum order quantity is the smallest run a factory will cut, and it exists because dyeing a fabric lot and setting up the sewing line are fixed costs per run. The MOQ you are quoted depends almost entirely on how custom the garment is, and it usually applies per color or per style, not across the whole order.
| Order type | Typical MOQ | What is custom | Lead time |
|---|---|---|---|
| Embroidery on stock scrub body | 50 per style | Decoration only | 2 to 3 weeks |
| Custom-cut, stock fabric | 150 to 300 per style | Pattern and fit | 4 to 6 weeks |
| Full custom fabric / private label | 300 to 500 per style / color | Fabric, color, pattern, label | 6 to 9 weeks |
Size the order to your team first, then pick the order type that clears its minimum without leaving dead stock. A 25-person clinic that wants a branded look almost always brands stock bodies with embroidery rather than commissioning a 500-piece fabric run, because a custom-fabric MOQ would force roughly 350 sets of garments nobody wears. If your calculated quantity sits below a custom minimum, consolidate colors: dropping from four colors to two often moves you from below minimum on each to comfortably above on both.
How do you brand scrubs so the logo survives industrial laundry?
Scrubs are washed hot and often, so decoration has to be chosen for durability, not just look. The three methods below behave very differently through 75 degree Celsius wash cycles and clinical-strength detergents.
- Embroidery. The most durable option for a clinic logo and name. Stitched thread survives the full life of the garment and reads as professional. Best for left chest, sleeve, and name-and-credential tags. Digitizing is a one-time setup per logo.
- Heat transfer / vinyl. Lower setup and good for small quantities or fine text, but the weakest through repeated hot washing, where edges can lift over time. Use it for short-run or temporary needs, not a program you expect to reorder.
- Dye sublimation. For all-over color and pattern on 100% polyester bodies. The design is dyed into the fibre so it never cracks or peels, but it works only on polyester and light base colors, so it fits fashion-forward or pediatric prints rather than a simple logo.
For most medical programs, embroidery on a stock or custom-cut body is the right call: it looks clinical, it lasts, and it clears a low minimum. Our comparison of sublimation vs embroidery vs DTF covers the trade-offs in detail, and the same digitizing standards we use for custom embroidered polo shirts apply to scrub decoration.
How many sets per person, and how should you split sizes?
Two numbers decide whether a scrub order is right-sized: sets per worker, and the size curve. Get the first from how the uniform is actually used, and the second from your real team, not an even spread.
For sets per worker, plan by role:
- Full-time clinical (3 to 5 shifts a week): 5 to 7 sets, so a clean set is always ready while others move through the wash.
- Part-time or low-soil clinical: 3 to 4 sets.
- Reception and admin: 3 sets.
Add a 10 to 15% buffer on top for new hires, shrinkage, and bleach damage. A short buffer up front is cheaper than a second short production run that misses the original dye lot. For the size split, a real healthcare workforce skews to the middle and carries a genuine plus tail, so an even split is the single most expensive habit in bulk uniform buying. A workable starting curve is 1% XS, 6% S, 22% M, 27% L, 22% XL, 15% 2XL, 7% 3XL. Adjust once you have your team's measurements, and build a separate run for men's, women's, and unisex blocks when you offer more than one fit.
What US compliance rules apply to bulk scrubs?
Scrubs sold and worn in the US carry a few obligations that a serious buyer should confirm in writing, and this is where a lot of overseas quotes go quiet. These are the ones that matter for a clinic program.
- FTC labeling. Every garment needs a permanent label stating fiber content, country of origin, and care instructions under the Textile and Wool Acts. Confirm the factory sews this in as standard.
- Skin safety. Ask for OEKO-TEX Standard 100 certified fabric, which is independently tested for harmful substances. It is the clearest signal that the fabric is safe against skin for long clinical wear.
- Fluid resistance. If the scrub is for surgical or high-exposure use, fluid barrier performance is rated by the AAMI PB70 levels (1 through 4). A general scrub is not a surgical gown, so do not let a supplier imply a standard scrub is a barrier product.
- Honest antimicrobial claims. An antimicrobial finish treats the fabric to resist odor and bacterial growth on the cloth. It does not make the garment a medical device and it does not prevent infection. In the US, marketing of antimicrobial textiles is regulated by the EPA and FTC, so any claim must be limited to fabric protection and backed by test data. We keep scrub antimicrobial claims to exactly that.
Alayki International is a real Sialkot factory operating through a US company you can verify, which is why we put labeling, certification, and test data in writing before production. See who we are and how we are structured if you want to check the factory-and-US-company setup before you commit.
What are the lead times for a bulk scrub order?
Build lead time into your order date so a busy hiring season never catches the team short. A typical custom scrub program moves through these stages:
- Quote and fabric swatch: 24 to 72 hours for a detailed quote, then a physical swatch kit for you to handle before you commit.
- Lab-dip and sampling: 7 to 10 working days for a physical sample with your logo and color, with color verified against your reference so reorders match.
- Bulk production: 3 to 5 weeks after sample approval, on a single dye lot with inline quality checks at cutting, sewing, and finishing.
- Shipping: air freight in about 5 to 12 days, or ocean freight for larger programs where cost matters more than speed.
Custom colors add a dyeing window on top, so if your team needs uniforms in three weeks, that points you to embroidered stock bodies rather than a full-custom fabric run. Our how it works page walks through the full path from tech pack to delivered bulk.
Frequently asked questions
What is the minimum order for custom scrubs?
It depends on how custom the garment is. Branding a stock scrub body with your embroidered logo usually starts near 50 pieces per style, because only the decoration is custom. A custom-cut scrub on stock fabric runs about 150 to 300 per style, and a fully custom fabric or private-label run needs roughly 300 to 500 per style and color. The minimum normally applies per color, not across the whole order, so confirm the exact figure in a written quote.
How much do bulk custom scrubs cost per set?
Factory-direct, a set of top plus pant runs about $9 to $22 before decoration and freight, depending on the fabric and the run size. Poly-cotton is the lowest cost, performance stretch and antimicrobial blends sit higher, and the biggest per-piece saving comes between 50 and 300 sets. Budget on landed cost, which adds embroidery, freight, and any duty to the factory price.
Which scrub fabric is best for long clinical shifts?
For 12-hour shifts, a performance stretch around 175 to 195 GSM (90% polyester, 10% spandex) gives the best mix of movement, breathability, and moisture wicking. For general wards and outpatient work a poly-cotton around 155 GSM is comfortable and durable. For surgical, dental, and infection-control settings, choose a silver-ion antimicrobial fabric with fluid resistance.
Will an embroidered logo survive hospital laundry?
Yes. Embroidery is the most durable decoration for scrubs because stitched thread survives the full life of the garment through hot industrial wash cycles. Heat transfer and vinyl are weaker over repeated hot washing and can lift at the edges, so they suit short-run or temporary needs rather than a program you plan to reorder.
Can you match colors on a reorder six months later?
Only if the color is controlled from the first run. We produce each order on a single dye lot, cut tops and pants from the same fabric so they match exactly, and retain a reference swatch so a later reorder is matched against it rather than guessed. Ask any supplier to record and keep your dye-lot reference before you place the order.
Get a scrub program quote
Send your headcount, fabric preference, and colors, and we will return a quantity plan, a size split, and an MOQ-matched quote with the fabric test data and labeling in writing. Request a quote to start, or talk through fabric and decoration options for your clinic first.
By Qasim Hussain, Founder, Alayki brand, and Managing Partner, QVR Associates.