Wasted uniform stock usually starts with a guess: an extra box of mediums "just in case", or a size ordered in a colour it doesn't come in. Collect real sizes from real people, check that every size exists in the colour you've chosen, and plan top-ups instead of stockpiling. It matters more once a logo goes on, because our refund policy says "All decorated items (i.e. items that have been branded or personalised using our decoration services) cannot be returned due to change of mind."
Step 1: collect sizes, don't estimate them
Ask each person for a size in each garment they'll get, not one size for everything. Someone who takes a medium polo may want a large in a hoodie they'll wear over other layers. Keep separate columns for men's, women's and kids' versions, because they use different size systems: an Aussie Pacific Hunter polo runs S to 9XL for men, 6 to 26 for women and 4 to 16 for kids. For how women's cuts differ, see our guide to women's work pants and shirts.
Trying garments on beats guessing. As our FAQ says, you can drop into the store without an appointment, and we keep samples there. Our guide to ordering embroidered work shirts has a few more habits for collecting sizes.
Step 2: check every size exists in your colour
A style's full size range isn't always available in every colour. Our listings say so in plain words, if you read to the end:
| Style | Sizes listed | The catch, per the listing |
|---|---|---|
| JB's 210 Polo | 2XS to 12/13XL | "12/13XL only in Black" |
| JB's Womens 210 Polo | 6 to 30 | "26, 28 & 30 only in Black, White & Navy" |
| AP Torquay Hoodie 1525 | XS to 3XL, 5XL, 7XL | "7XL in Navy & Black" |
| AP Hunter Polo 1312 | S to 3XL, 5XL, 7XL to 9XL | "Up to 5XL in all colours" |
Two more things to look for. Most of our Aussie Pacific men's listings, including the Torquay and Hunter above, jump from 3XL to 5XL with no 4XL, so a 4XL wearer needs a decision before the order goes in. And the smallest sizes can be limited too: the JB's Womens 210 says "Size 6 available in Black, Navy, White, Red, Purple, Lt Blue". If anyone sits at either end of the range, check their size in your colour first, then lock the colour in.
Step 3: note the differences inside one style
Men's, women's and kids' versions of a style aren't always identical apart from size, and the differences can affect your logo:
- The Aussie Pacific Tasman tees have a "V-neck self fabric neck band (ladies' only)", while the men's and kids' have a round neck.
- The JB's 210 polos have a 3-button placket for adults' sizes and a 2-button placket on the women's and kids' versions.
- The Torquay men's hoodie lists a "Flat tie cord (men's only)".
Tell us which versions are in the order. We go over your artwork with you before production, including where the logo sits and how big it is, so a V-neck or a different placket gets planned for rather than discovered on the finished shirt.
The styles in this guide, and how they wear
Fabric and cut change how a size feels, so it helps to know what each style is before people choose. All of these sit in our polos and hoodies ranges.
- Hunter polo. A 210gm poly/cotton pique whose side vents, the listing says, "further enhance the comfort and look". It's a dependable everyday staff polo, though above 5XL the colour choice narrows and there's no 4XL.
- JB's 210 polos. A "Classic fit" in 210gsm pique, "easy care and reduced pilling", which suits teams that wash their uniform often. The broad size spread is the strength; the extreme sizes come in only a few colours.
- Tasman tees. A 150gm polyester "Moisture removal micro-knit" with "Easy care fabric for when you are on the go", a sensible pick for active or event crews. The women's version is a V-neck, and the men's and kids' listings warn that neon colours may vary from what you see on screen.
- Torquay hoodie. A 340gm, 80% cotton brushed fleece that the listing calls "Ideal for layering in cooler weather". Because it goes over other clothes, it's the garment most worth sizing separately. There's no women's version, and 7XL comes in Navy and Black only.
Step 4: plan for new starters without stockpiling
A pile of spare sizes is the classic source of waste. A few ways to keep it small:
- Order spares only where you can name the need, such as a known new starter, or a size that wears out faster in your crew.
- Top up instead. A digitised embroidery logo stays on file with us after the first order, which makes a handful of extra shirts later a much smaller job than a fresh start.
- Remember the garments come from suppliers. A style or colour that's easy to get today may be harder to get later, so if a style matters, ask about it before a big hiring round.
- Keep the size list current as people join, leave or change size. Our ordering guide's reorder tips cover what else to keep on record.
Before you sign off
Run one last check of the order against your list:
- The garment count matches the number of people, plus only the spares you chose on purpose.
- Every line has the style, the version (men's, women's or kids'), the colour and the size.
- Anyone at the top or bottom of a size range has been checked in your colour.
- Anyone still missing a size has been chased, not guessed.
Ten minutes here beats a box of shirts with your logo on them that nobody can wear.
Got your size list together? Send it, along with your chosen styles, colours and logo, via our custom workwear enquiry form, and mention any new starters you're expecting.
