When a global giant announced its withdrawal from manufacturing in Poland, an entrepreneur from Zgierz took over the infrastructure of the Płock facility, proving that garment production in Europe can still make sound business sense. The combination of tailoring expertise, automation and flexible logistics demonstrates a new economic rationale for denim manufacturing on the continent.

The story began in mid-2024, when an American apparel group ended operations at its Polish production facility in Płock after 33 years. The management board’s decision was based on a straightforward calculation: rising labour costs in Europe and challenging market conditions led the brand to close the local factory. The production complex, which for decades had supplied the European market with high-quality trousers, faced permanent closure and the sale of its machinery.

For many observers, this was another sign of the apparel industry shifting towards Asian markets. Yet where the international group saw a lack of profitability, Polish entrepreneur Daniel Kurowski saw ready-made infrastructure and the potential for European nearshoring. He took over part of the facility, modernised the machinery and brought together more than 50 experienced tailors, technologists and pattern makers from the former workforce. Only after securing this infrastructure and assembling the team did he establish the Jan Spekter brand.

Today, the Płock facility is not only operating but producing trousers that reach customers in Tokyo, Hong Kong, London and New York. The story offers an interesting example for European purchasing managers and operations directors. It shows that shorter supply chains and manufacturing in the heart of Europe can provide a flexible and economically viable alternative.

From craft tradition to technological precision

Daniel Kurowski is an industry practitioner with many years of experience, having worked his way from sewing factories in Łódź and Zgierz to organising large-scale production. Over the years, he gained experience coordinating manufacturing for, among others, rapidly growing streetwear brands. When creating Jan Spekter, he focused on intensive development, investment in machinery and ensuring operational continuity.

This manufacturing heritage now forms the foundation of the company’s distinctive know-how. By taking over part of the Płock infrastructure, Kurowski brought together specialists who had spent more than three decades fulfilling orders in accordance with some of the most demanding standards in the market. Combining their expertise with new technical capabilities made it possible to build a facility with substantial production capacity.

“If I were to compare our factory to the automotive industry, it would be as if we had been given the opportunity to take over the facilities of an established luxury brand together with all its technological know-how, machinery and people,” explains Kurowski. “We work in the same buildings, with the same outstanding technologists, pattern makers and sewing specialists for whom quality is a matter of professional pride. We combined these capabilities, built up over decades, with our own vision for the Jan Spekter brand. The result is a modern premium-class production centre operating under a Polish name.”

This was not Kurowski’s first undertaking of this kind. Earlier, he had taken over a sewing factory in Nowe Miasto nad Pilicą in a similar way, preserving the expertise of a team whose skills would have taken years to recreate on the labour market.

Geopolitical nearshoring: speed and flexibility instead of long-distance imports

For years, moving production to Asia appeared to be the only economically justified option. Today, however, European markets are increasingly exposed to the risks associated with long-distance supply chains. Wages in the Far East are steadily rising, while logistics costs and geopolitical instability are becoming a tangible burden.

Under these conditions, manufacturing in Europe offers clear operational advantages. While shipping finished garments by sea from Asia typically takes three to four months, Jan Spekter can deliver completed production batches to customers in Germany, Belgium, the Netherlands or the United Kingdom within just a few working days. Instead of ordering large volumes of a single model many months in advance, brands can test the market with a smaller trial batch produced in Płock. If a model proves successful with customers, the facility can flexibly replenish production during the same season.

Local production also makes businesses significantly more resilient to global logistics disruptions, such as blocked shipping routes or sudden increases in freight rates. Choosing a supplier within the European Union also supports ESG objectives by helping to preserve specialised jobs and build a transparent supply chain.

Compliance, sustainability and cost optimisation

European consumers and market regulators are placing increasingly stringent demands on environmental performance. Jan Spekter manufactures using certified, safe fabrics, while the entire denim finishing and washing process is carried out in full compliance with strict EU environmental standards. The company also focuses on durability and timeless cuts, providing distributors with an important commercial argument when building long-term customer loyalty.

Although labour costs in Europe are higher than in eastern markets, the difference can be effectively reduced through automation and appropriate production organisation:

“Europe does not lack capital or technology,” Kurowski emphasises. “With properly structured and stable production volumes, we are able to implement advanced, automated sewing lines. This significantly reduces the impact of labour costs on the unit cost of the finished product. We compete through technology, greater consistency and logistical proximity.”

A proven partner for international brands

The contracts already being fulfilled demonstrate that the Płock sewing facility can deliver to international standards. The factory regularly handles orders for brands from the United Kingdom and France, while finished trousers produced in Płock are shipped directly to customers in Asia and North America.

For European business partners, this means access to a production base that meets rigorous technical requirements while ensuring consistent quality, reliable lead times and full control over every stage of the manufacturing process.

Jeans can still be made in Europe. In the face of geopolitical change, environmental requirements and the need to shorten supply chains, local manufacturing is becoming a well-considered strategic option for many brands. The Jan Spekter facility in Płock fits into this trend as a stable and modern production base.

https://janspekter.com/