Reordering Scrubs: Keeping Colour and Fit Consistent Across Batches

Scrubs from a reorder rarely match the first batch perfectly unless someone plans for it. Fabric is dyed in lots, and two lots of "navy" can differ visibly when staff stand side by side. The fix is to keep a physical reference (a retained garment or fabric swatch), write down the exact fabric and colour specification, and agree how a new batch will be checked against that reference before it is sewn.

This guide explains why colour and fit drift between orders and how to keep a clinic's scrubs consistent over years of reorders. For why colour changes during washing, see our sister article on why scrubs fade.

Why reorders don't always match

Dye lots

Fabric is dyed in batches called dye lots. Even with the same recipe, small differences in dye uptake, water, temperature and the base yarn mean each lot comes out slightly different. Within one lot the colour is consistent; between lots it can shift a little lighter, darker, warmer or cooler.

On their own, those differences are often hard to see. They become obvious when new scrubs from lot B are worn next to six-month-old scrubs from lot A, especially in a team that colour-codes by role.

Faded originals

The second problem is that the "original" colour no longer exists. Scrubs washed hot several times a week lose some depth of colour over time. A brand-new reorder may match the first batch exactly and still look different from what staff are wearing, simply because the old garments have faded. This is why you need to compare against a reference that has not been worn.

Fabric changes

If a supplier changes mill, base fabric or blend, colour can shift even with the same dye recipe, because polyester, cotton and viscose take dye differently. A change from poly-cotton to a stretch polyester-viscose-elastane blend can change both shade and sheen.

Fit drift

Fit can drift too. A new pattern, a different factory or a changed size chart can mean a medium from the reorder fits differently from a medium in the first batch. Staff notice fit changes as quickly as colour changes.

How colour matching is measured

You do not need a laboratory, but it helps to know the language suppliers use.

• Visual assessment in a light booth. Colour is judged under controlled lighting, typically including a D65 source that simulates daylight, and often a store-type fluorescent (TL84) and incandescent light as well.
• Metamerism is the effect where two samples match under one light and not under another. A navy that matches in daylight can look different under ward fluorescent tubes. Checking under more than one light source catches this.
• Delta E (ΔE) is a number from a spectrophotometer that expresses the colour difference between a sample and a standard. Smaller is closer.

There is no single universal pass mark. Supplier guides quote different tolerances, and the number depends on which formula is used (for example CMC 2:1 or CIEDE2000), so a ΔE of 1.0 under one formula is not the same as 1.0 under another. If you specify a numerical tolerance, agree the formula, the light sources and the threshold together with your supplier. For most clinic orders, a careful side-by-side visual check against a retained standard under daylight and indoor lighting is practical and sufficient.

Set up for consistency from the first order

The easiest time to protect future reorders is before the first one ships.

Keep a master reference

1. Retain at least one unworn top and one pair of trousers from the first approved batch, per colour.
2. Label them with the order date, colour name, fabric and supplier reference.
3. Store them away from light, in a sealed bag, in a cool cupboard. They are your colour and fit standard.
4. Ask the supplier to keep their own reference swatch from the same lot.

Write down the specification

A colour name such as "teal" or "navy" is not a specification. Record:

Item	Example
Fabric composition	65% polyester / 35% cotton
Fabric weight and weave	As supplied on approved sample
Colour reference	Supplier's colour code plus retained swatch
Finish	e.g. fluid-repellent, if used
Garment styles	Style codes for top, trousers, cap
Size chart	Supplier chart with measurements, saved as a file
Embroidery	Logo file, thread colours, name font and size

Keep this in the same folder as the staff name list. A detailed specification is also the basis of a fair comparison if you ever go out to tender; see our guide to hospital uniform tender specifications.

Order sensibly

• If the budget allows, order a buffer stock in common sizes from the original lot. Spares from the same lot match the team exactly.
• Avoid splitting one large order across several suppliers or fabrics for the same colour.
• For big roll-outs, ask whether the order can be cut from a single lot, or how lots will be allocated so each department receives consistent fabric.

The reorder process

Treat a reorder as a short approval, not a repeat purchase.

1. Send the specification and photos of the retained standard to the supplier, plus the original order reference.
2. Ask which fabric lot will be used and whether the base fabric or mill has changed since the last order.
3. Request a fabric swatch or sample garment from the new lot before bulk cutting, for larger reorders or when the colour is used for role coding.
4. Compare under two light sources. Lay the new swatch on the retained, unworn standard. Check by a window in daylight and under your clinic lighting.
5. Check the fit of one sample in the most common size against the retained garment: chest width, length, rise and leg length.
6. Approve in writing and note the new lot reference on your specification.

Our sample approval guide covers wear trials and wash tests in more detail.

Matching scrubs you already have

Sometimes the original supplier is no longer available and a clinic needs new scrubs that sit alongside existing ones. Matching is possible, but set expectations:

• Send an unworn garment if you have one. A worn garment gives the supplier a faded target.
• Expect a close match rather than an identical one if the fabric base is different.
• If the difference is noticeable, consider changing a whole role or department at once rather than mixing old and new within the same team.
• Where colour coding is critical, ask for a swatch to approve before production.

When to accept a small difference

Perfect consistency costs time. A sensible approach is to be strict where colour carries meaning and relaxed where it does not.

Situation	How strict to be
Colour coding by role, patient-facing teams	Strict: approve swatch, compare under two lights
Single-colour team, new joiner or two	Moderate: visual check against retained standard
Back-of-house, laundry spares	Relaxed: same colour family is enough

Reorder checklist

• Unworn reference garment retained per colour, labelled and stored dark
• Written specification: fabric, colour code, styles, size chart, embroidery
• Supplier asked about lot and any fabric or mill change
• Swatch or sample compared in daylight and under clinic lighting
• Fit checked against the retained garment
• New lot reference recorded

Reordering with MISHAREN

MISHAREN makes medical scrubs to order at its own unit in Konni, Kerala, India and imports each order to the UAE. Clinics approve a sample, the approved specification is kept on record so reorders match, and we can work to match existing scrubs on request. If you are planning a reorder or need to match a colour you already use, share your specification or a reference garment through our contact page for a quotation.