Wow this thread is still active.
We found the problem, it was specifically Black Sulfur Dye.
The shirts we were buying were not washed after Dying, and the Sulfur in the Dye was continually eating through the cotton as we stored them.
We have resolved this issue mostly by not dealing with people who use Sulfur Dyes, there are better dyes available for a bit larger cost that we are more than willing to pay for.
If you are in the business of selling shirts you are dying yourself, and use sulfur, I would suggest possibly educating your customers about non sulfur based dyes that they can pay a bit more for you to produce.
We are a retail seller of shirts, not a wholesaler, so storage is an issue, as it will be for many of your end customers. We were dealing with people who were trying to maximize their profits per sale, and not educating their customers about it.
I am likely not the only one who had to toss out thousands of t-shirts and then stop business with them entirely for their unwillingness to explain the limited lifespan of their t-shirts to us beforehand. Some of the ripping shirts made it into customer's hands which forced us to either refund them, or send them new shirts, in addition we got a few bad reviews on Social media because of it.
To make things worse, some of the companies we dealt with, initially did not use sulfur, but switched to it to try and maximize profits later on, so while we thought their products stored well due to previous instances of storing it, it was no longer the case.
In the cases where we still have to purchase a few of the Black Sulfur dyed shirts, we are washing them after purchase, we expect this will increase the lifetime of them for storage, but have not yet had the time to test the theory out fully.