Skip to content
Branton Promo Group

Apparel

The size-audit no one runs, and why it costs you

Reference sets, mill differences, and the reason your team keeps asking for exchanges.

January 14, 2026 · 7 min read

Apparel exchange rates are a hidden line item on every uniform program. The most common cause isn't the wearer. It's the assumption that a large from one mill is a large from another.

Build a reference set

Order a fit sample of each size in every fabric you standardize on. Keep it in a labeled bin. Every future re-order references the bin, not a spec sheet.

Audit the return rate quarterly

Track exchanges by SKU and size. A single style that's off by a full letter is worth pulling and re-fitting; the amortized cost of chasing exchanges usually exceeds the cost of re-tooling.

Start here

Ready to run a better merch program?

Start with a shortlist, a store setup, or a specific campaign. Whatever the entry point, we'll take it from there.

Start a ProjectTalk to a merch strategist