Zenith Active Canada: Seamless Gym Sets Built on Pbt/Polyester Blend
Zenith Active is a growing Canada-based activewear brand focused on seamless gym sets. When the design team prepared to expand its seamless gym sets range, it needed a fabric partner that could deliver consistent quality, realistic lead times and documentation that would stand up to retail audits.
The challenge
The brand's main pain point was high MOQ blocking new colour testing. The previous supply chain relied on a generic trader who could not provide construction sheets, test reports or reliable shade continuity. As launch deadlines tightened, the risk of delays and quality claims grew.
The solution
Our team proposed a dedicated PBT/polyester blend programme built around low-MOQ trial runs with recycled yarn. We started with A4 lab dips and a full construction sheet covering GSM, width, stretch recovery and colour fastness. Once the brand approved the hand feel and performance targets, we moved to a pre-production lot for fit sampling.
Implementation
- Development: 5 days for lab dips and physical samples.
- Approval: colour, hand feel and stretch tests signed off in two rounds.
- Bulk: colour-consolidated dyeing to reduce shade variation.
- QC: inline inspection plus final random inspection before packing.
Results
The new PBT/polyester blend programme helped Zenith Active lowered fabric defect rate below 1%. The seamless gym sets line launched on schedule and received positive feedback for fit, comfort and wash durability. The brand has since expanded the programme into additional colours and styles.
"The fabric development process was transparent from the first sample. We finally had the data we needed to brief our retail partners with confidence." — Zenith Active Product Team
Key takeaway
Switching from a trading model to a mill-direct development approach removed the hidden risks in the supply chain. With documented construction, consistent shade management and inline quality control, Zenith Active could focus on design and marketing rather than firefighting production issues.
