How Many Custom Overalls Should You Order? Planning Sets, Spares, and Reorders

Published October 13, 2026. Last updated October 13, 2026.

The right number of custom overalls equals your crew size times the sets each worker needs to cover a laundry cycle, plus spares in your most common sizes for new hires and damaged garments. Customized Overalls quotes by style and size, sends a free mockup within 24 hours and keeps your approved design on file for matching reorders.

How many custom overalls should a crew order per worker?

Most crews should order custom overalls based on how often the garments get laundered, not just on headcount. A worker who wears overalls every day and sends them out for washing needs at least one set on the body and one set in the wash, or that worker ends up in street clothes on laundry day. Customized Overalls builds every quote around the number of people, the number of sets per person and the style each job needs.

Start with a simple count of everyone who will wear the overalls in the field. Then decide how many sets each person needs to cover a full laundry cycle. Crews that wash at home on weekends can often run on fewer sets than crews that use a uniform service with a pickup schedule, because a service holds garments for days at a time.

• Daily wearers on a laundry service: plan for several sets per person so a clean pair is always on the hook.
• Daily wearers who wash at home: a second set per person usually covers the gap.
• Occasional wearers: supervisors, estimators and drivers may only need one set each.

Write those numbers down by style before you request a quote. A painting contractor might need white painter’s overalls for the whole crew but denim bib overalls only for the foreman who also does carpentry. Splitting the count by style keeps you from buying garments nobody wears.

Should you order spare custom overalls beyond your current headcount?

Yes, a small stock of spare custom overalls almost always pays for itself in fewer emergency reorders. Spares cover new hires, garments ruined by a chemical spill or a torn knee, and the worker who left a set in the truck at the wrong job site. Without spares, every one of those moments turns into a fresh order with its own proof and production window.

Build spares into the original order rather than adding them later. Because the logo, thread colors and placement are already approved, spares from the same run match the rest of the crew exactly. A separate order weeks later can still match, but it takes another trip through production that runs about 2 weeks.

Decide spare quantities by size, not as a flat extra. Spares should cluster in the sizes your crew wears most, with a few in the next size up and down. A spare in a size nobody fits is just shelf stock. If you are unsure how your crew’s sizes spread out, the sizing guide on this blog walks through collecting measurements before you count spares.

Store spares flat or folded in a dry, closed cabinet at the shop. Keep them in their original bags and label each bag by size so a crew lead can grab the right one without unpacking the whole box.

How do new hires and turnover change your custom overalls order?

Turnover changes a custom overalls order more than most contractors expect, because every new hire needs a full set on day one. If your business hires steadily through the year, plan the order around the crew you will have over the next few months, not just the crew on payroll today. Customized Overalls can help you balance spares now against a planned reorder later.

Think about three groups when you count:

1. The core crew: long-term employees who need full sets in their exact sizes.
2. Expected hires: roles you are actively recruiting for, covered by spares in common sizes.
3. Seasonal or project workers: people who join for one job and may not stay, often best served by disposable coveralls or a simpler style.

Leave individual names off spare garments. Name embroidery is a great touch for long-term employees, but a spare with a former worker’s name on the chest cannot go to anyone else. Keep the company logo on every garment and add names only for the core crew, so spares remain ready for whoever walks in next.

Which overall styles should you split your order across?

Split your custom overalls order across styles only when different jobs on your crew genuinely call for different protection. A single style keeps sizing, approval and reorders simple. A mixed order makes sense when some workers face heat, cold, paint, grease or flame risks that others do not.

The minimum order of 12 applies to the order as a whole, so talk through a mixed order on your quote request. Customized Overalls will confirm how styles and colors can be grouped before the mockup is built.

When does it make sense to order more custom overalls at once?

Ordering more custom overalls at once makes sense when your crew is stable, your logo is not about to change and you have dry storage for the extra garments. A larger order means fewer proof cycles, fewer production windows to plan around and garments that match perfectly from the same run.

A larger single order also simplifies budgeting. Instead of a string of small invoices through the year, you get one approved design, one delivery and one line in your books. Larger quantities can also change what you pay per garment, so ask Customized Overalls to quote a couple of quantity options side by side.

Hold back on a big order in a few situations:

• You are planning a rebrand or new logo in the coming months.
• Your crew size is about to change sharply, up or down.
• You have not yet tested how a style holds up on your job sites.
• Storage at your shop is limited or damp.

In those cases, order what the current crew needs plus a modest stock of spares, and plan a reorder once the picture is clearer.

How do you stage reorders so custom overalls always match?

Staging reorders keeps custom overalls consistent across every batch your crew wears. The key is to save the approved proof and the exact details of the first order: style, color, logo placement, thread colors and any name format. With those details on file, a reorder starts from a known design instead of a new one.

Set a reorder trigger rather than waiting until the spare cabinet is empty. A practical trigger is the point where spares in your most common size run low. Because standard production takes about 2 weeks after approval, reordering at that point leaves time for the new batch to arrive before anyone goes without.

1. Keep a simple sheet listing spares on hand by style and size.
2. Check it when you onboard a new hire or retire a damaged garment.
3. Request a quote when your most-worn size gets low.
4. Reference the original order so the mockup matches the first run.
5. Approve the proof and track the delivery date against your hiring plan.

Customized Overalls still sends a free mockup within 24 hours on a reorder, so you can confirm nothing has drifted before production starts. You pay nothing until you approve the design.

What should you send with your quote request to get the quantity right?

Send Customized Overalls a clear breakdown of style, size and quantity with your quote request so the first mockup reflects the order you actually need. A quote built on a rough total often has to be reworked once sizes come in, which adds a round of back and forth before production can start.

A helpful quote request includes:

• The style or styles you want, with links to the product pages if that helps.
• Counts by size for each style, including spares.
• Your logo file and where you want it placed.
• Whether any garments need individual names.
• The date your crew needs the overalls on the job.

If a few sizes are still unknown, say so. Customized Overalls can quote the confirmed portion and help you plan spares for the gaps. The free mockup arrives within 24 hours, revisions are unlimited and free, and the minimum order is 12 across the order.