Gymnastics apparel manufacturer Sylvia P has upgraded its local factory in Queensland to a new 3,000 square metre facility.
This is well over four times larger than its original size in 2018, then at just 500 square metres.
Speaking with Ragtrader, Sylvia P managing director Thomas Pichler says the move came after the company opened up trade into the United States in 2018, sparking significant growth.
Today, 80 per cent of Sylvia P’s revenue comes from US sales.
“At the time, we were a team of just 20 operating out of a 500sqm warehouse. By 2020, we had added another 300sqm, and by 2022, another 300sqm,” Pichler says.
“Despite these expansions, production was split across three sites, requiring us to constantly transport fabrics and garment components between locations. It was inefficient, challenging, and we were bursting at the seams."
By 2023, Pichler says the business needed a new solution.
“Our options were to add yet another smaller warehouse or take a bold leap and create a purpose-built, all-in-one factory. We chose the latter, completing the move to our new 3,000sqm facility in November 2024.”
According to the managing director, the new “state-of-the-art” space is a multi-million-dollar investment, hosting over a million dollars’ worth of advanced machinery, making it one of the largest and most advanced textile factories in Australia.
Key technologies include three CNC cutting machines, in-house sublimation fabric printing and pressing equipment, and an embellishment lab capable of placing over 250,000 crystals daily.
Sylvia P is a Swarovski Cystal Branding Partner, and claims it is Australia’s largest purchaser of loose Swarovski crystals, among an exclusive circle of just 200 brands worldwide.
“Our air-conditioned sewing room features more than 60 machines, ensuring precision and comfort for our team,” Pichler adds. “Although the facility is larger than we currently need, it has been built in a way where each department has the space for twice the machinery and can double capacity as we continue to grow over the coming years.
Beyond production, the facility also includes an in-house photo studio, a lunchroom accommodating up to 100 people, and “a welcoming aesthetic designed to inspire creativity” for the team.
Speaking on the US dominance, Pichler says this is driven by the immense popularity of gymnastics in the market, providing a thriving base of athletes and teams seeking quality gymnastics apparel.
In turn, he says this is buoyed by its made-to-order business model, which takes up a majority of its garment production. The brand also sells other styles online including crop tops and shorts, with prices ranging from around $40 to $80 per style.
Pichler says production times can vary depending on workload. During slower periods, it typically takes about four weeks to complete a garment. However, in busier seasons, it can extend to up to 12 weeks due to high demand.
“Thanks to our advanced facility and dedicated team, we have the capacity to produce around 500 units per day,” he says. “In urgent situations, we’ve even completed garments in a single day.”
The Sylvia P business was launched in 1994 by Sylvia Pichler. Thomas Pichler said despite most of the apparel manufacturing market moving offshore, this hasn’t been a consideration for him or the family business.
“The decision to remain local is deeply rooted in the company’s commitment to quality, customisation, and responsiveness,” he says. “We keep production local to accommodate low minimum order requirements, offer the high level of product customisation our customers desire, and ensure the exceptional product quality that defines our brand.
“We have found that manufacturing in our own factory locally enables us to maintain tighter control over every aspect of production, from materials to final finishes.
“This hands-on approach not only guarantees superior quality but also allows the company to remain agile, meeting customer needs with precision and care.”
Pichler adds that the small size of the textile industry in Australia means there are fewer skilled workers available for its niche
“We have to provide a lot of on the job training,” he says.
“Another significant challenge has been the lack of locally made or used machinery and technical knowledge in our field. It took us years to source the right equipment from offshore suppliers, and once we had it, we had to learn how to use it ourselves and train our team on the job.
Despite these obstacles, Pichler says he and the team are committed to staying onshore.
“We’ve found solutions by investing in training, building a knowledgeable team, and ensuring we’re continually improving and keep the textile craft alive in Australia,” he says.
Alongside the US growth, Sylvia P has recently been announced as the Official Gymnastics Wear Partner of Gymnastics Australia.
Pichler says this partnership means that all Australian National Team uniforms will now be crafted by Sylvia P for the next four years.
“Our influence extends beyond Australia, as we proudly supply gymnastics apparel to some of the largest NCAA colleges in the USA, including renowned programs like the Florida Gators, UCLA, and Stanford."