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Manufacturing Programme
Fersan Tekstil is a vertically integrated polyester knitted fabric manufacturer in Çorlu, Türkiye; the training programme builds not a single fabric but a set of complementary layers.
Training wear is not one garment but three thermal states in sequence. During the warm-up the body is cold and heat output is low; in the main set output peaks and sweating starts; in the cool-down output stops but the garment is wet — the moment when chilling happens fastest. No single fabric can serve all three, because the insulation you want during the warm-up becomes a burden during the cool-down.
So the programme is built as a layer set. Three-thread fleece and brushed french terry form the body of the warm-up top and the tracksuit; brushing takes its insulation not from the yarn but from the air held at the surface. Micro fleece insulates as a thin mid-layer without adding bulk; double-face fleece gives both insulation and surface durability in the outer layer; and interlock jersey is the next-to-skin base for the main set. We decide brushed versus unbrushed together, according to where the fabric will sit.
280–380 g/m²
240–360 g/m²
100–200 g/m²
200–320 g/m²
160–250 g/m²
Weight windows come from catalogue data; final specs are confirmed on a sample.
| Minimum order (MOQ) | 500–1,000 kg per colour — varies by fabric |
|---|---|
| Lead time | Typically 3–4 weeks from order confirmation to dispatch |
| Sampling | Sampling begins after a short technical consultation |
| Response time | Quotation requests answered within 2 business days |
| Delivery terms | EXW · FOB · DAP — shipping plan confirmed with your quotation |
| Capacity | ~750 t/month knitting + dyeing at the Çorlu mill (since 1982) |
Figures are typical ranges; exact terms are confirmed with your quotation.
From box size and weight, find the estimated number of cartons a container holds and its fill.
Estimated — indicative value.
It depends on the roll/carton size and weight. A 40' container offers ≈ 67.57 m³ and a 26,600 kg payload limit; the tool divides those by your box volume and weight, then takes the smaller. For a 0.072 m³, 20 kg carton that is an estimated 938 units.
A 20' container carries ≈ 33.14 m³ / 28,200 kg, a 40' ≈ 67.57 m³ / 26,600 kg. The 40' gives roughly double the volume but a similar payload limit — so for heavy cartons the binding limit is often weight, not volume.
A 40' HC (High Cube) is 30 cm taller than a standard 40' (2.69 m interior height), giving ≈ 76.04 m³. It is preferred for light but bulky fabric rolls because it allows one more stacking layer.
The calculation assumes simple stacking; actual loading varies with pallet size, carton orientation, stacking pattern and door clearance. Contact us for an exact load plan and shipping quote.
We build the layer set with you: the thermal range each layer targets is defined, and brush depth and surface hand are set accordingly. Because post-wash fuzzing and dimensional change are critical in brushed structures, we set compacting against your target wash count and report the outcome with tests.
Applications: Sportswear Fabrics
Related calculators: Container Loading Calculator — 20' · 40' · 40' HC (estimated) · Yarn→Fabric Cost Calculator — ₺/kg · ₺/m · $ · € · Meter ↔ Kilogram (Roll) Converter
Related guides: Brushed, Unbrushed and Fleece: Where Warmth Comes From in Polyester Knits · Fleece and Scuba: Structured Polyester Knits · Compacting & Residual Shrinkage: How Compactors Lock In Dimensional Stability
The link pre-fills the quote form with the fabrics on this page.
It depends on where the fabric sits in the layer order. Brushing insulates by trapping air at the surface, which is what you want in warm-up and cool-down layers. In the next-to-skin layer of the main set, that same air space means weight and slower drying once it wets out — there, an unbrushed structure is the right call.
Fuzzing is the joint outcome of brush depth, yarn selection and heat-setting. Keeping the brush as shallow as it can be while still giving the hand you want extends life appreciably. We define your target wash count at the outset and report fuzzing and pilling at that count.
Not necessarily, and often not ideally. The top prioritises bulk and insulation; the bottom prioritises freedom of movement and dimensional stability at the knee. Running two different structures from the same dye bath does not break the suit look; we verify the shade match with a lab dip.
The typical build is a thin unbrushed base next to the skin, a light insulation layer over it, and a wind-blocking shell outermost. On the fabric side we supply the first two layers; where the shell needs a woven or a lamination we say so up front and state plainly what falls outside our scope.
The 500–1,000 kg per colour band applies to each fabric separately, which in a layered set means opening the same colour across several fabrics. The most efficient route is to go deep on a limited palette. Sampling begins after a short technical consultation.
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