Day 2: "Why can’t I order just 50 yards of custom color?"

Welcome back to Day 2 of our experiment: My Dad vs. The Algorithm.

We are taking the top questions AI says you are searching for, and getting the gritty, real-world answers from my dad, Ira—who has been manufacturing fabric in Los Angeles since 2001.

The Question

Day 1 we talked about time. Today, we are talking about volume. The AI says one of the most frustrating things for new brands is Minimum Order Quantities (MOQs). specifically:

"Why can't I order 50 yards of a custom color? Why do I have to buy so much?"

The Answer

Ira:

Because you can’t buy one bottle of ketchup at Costco. You have to buy the two-pack of the giant bottles to get that price. We aren't a fabric store. In fact, we supply the fabric stores. I’m not going to steal business from the people buying from me—that hurts us both in the long run. If you want to buy small amounts, you go to a retailer (the grocery store). But if you want custom manufacturing direct from the source, you have to be ready to buy the 'family pack.

The Reality Check

Ira’s Costco analogy is spot on, but there is also a very technical reason why we can’t just "whip up" 50 yards of custom Sage Green for you.

Why can't you order just 50 yards? For the same reason you can't buy a single bottle of ketchup at Costco. Ira breaks down the math of manufacturing vs. retail.

1. The Machine Mechanics Fabric dyeing happens in massive industrial machines, not a kitchen sink. These machines require a minimum volume of water, fabric, and chemical load to run correctly. If we put 50 yards of fabric in a machine built for 1,000 yards, the fabric just sloshes around. It doesn't circulate properly. This leads to uneven color, streaks, and "technical failure." The fabric literally won't come out right.

2. The "Fixed Cost" Problem Whether we dye 1,000 yards or 200 yards, the machine uses the same amount of:

• Water

• Electricity

• Labor time to load and unload

• Machine time

If a dye machine takes 6 hours to run a cycle, and we fill it with a tiny order, we are losing money. If that machine is occupied for a 200-yard order, it means we can’t run a 1,000-yard order during that time.

3. The Math Can you get small quantities dyed? Yes, but the math changes. If you force a factory to run a small load, you usually have to pay the "whole machine" price. You are paying the full cost of a 1,000-yard run, but spreading it over only 200 yards. That makes the price per yard skyrocket.

So, when we say "No" to small custom orders, it’s not because we are being difficult. It’s because the physics of the machines—and the economics of the business—just don't work.

The "In-Between" Problem

Here is the dilemma many small brands face:

• Buying Retail: You can buy small amounts, but you are limited to whatever colors they have on the shelf. You can't pick your own unique shade and their garments are priced out of the market.

• Manufacturing Custom: You get total freedom to pick any color, but you have to hit high minimums .

The Solution: Our Stock Program

We realized there was a huge gap for brands that are growing—too big for Joann Fabrics, but maybe not ready for 1,000 yards of custom dye.

That is exactly why we started our Stock Program.

We wanted to bridge that gap. We take the exact same premium, Made-in-LA fabric that the big brands are using, and we make it accessible to small businesses. It allows you to get professional-grade quality without the "technical failure" or the massive "Costco-sized" commitment.

Tune in tomorrow for Day 3!

Need small quantities? Check out our Stock List for fabrics you can buy by the roll!