Regardless of whether polo shirts with embroidery for employees, printed t-shirts for events, or loose DTF are ordered from us – from the moment the order is placed, a series of production processes is initiated. While placing an order for decorated clothing is quite simple, few realize how much is needed to meet customer expectations and how much work each stage of production requires.
In the article below, we present the “journey” of your order – from the very beginning until shipment.
Office
This is where we first come into contact. We help you realize your projects, suggest solutions that will best influence the final effect of the decorations. We advise which decoration techniques will work best for the project, making corrections to files if needed.
We also handle ordering goods, maintaining documentation, invoicing, etc.
If the order concerns screen printing or transfers, we prepare films with graphics to later expose them onto screens.
Once all the order details are established, we pass it on to production – to properly prepare for the arrival of goods, equipment setup, and proper time organization.
Goods before production
The goods to be decorated arrive at our facility. At this stage, they are verified – unpacked, counted thoroughly, and checked for damages.
If everything is correct, the goods are forwarded where the quantity and quality of the textiles are once again verified. Then they are placed in an appropriate location, from where designated personnel take them directly to production.
The goods are frequently inspected, which allows quick detection of shortages or defects and efficient ordering of missing pieces.
Production
After initial verification, the goods move to the production hall where – depending on the chosen technique – the decoration is applied.
Screen Printing
Before printing on the material begins, the screens must be prepared. The film with the graphic (or its layers if the project has many colors) is attached to a stretched screen coated with light-sensitive emulsion, then exposed to UV light.
The light hardens the emulsion, creating “holes” through which the paint can pass. Then the emulsion is washed off and the screen is set aside to dry in a dark place.
This process requires precision – errors may occur such as mechanical damage to the screen or stains from insufficient washing, resulting in unwanted paint seepage.
The finished and dry screen must be taped carefully to prevent leaks. Even the tape must adhere perfectly – any oversight can cause errors on the material. Taping methods vary depending on the type of paint used.
The prepared screen is then given to the printer and assistant, who mount it in the correct places. For multicolor projects, a single machine may have up to 11 screens, including one for the base layer.
Before actual production, test prints are made on similar materials – checking parameters and the positioning of the matrices.
If everything is correct, paint is pressed through the screen using squeegees, and the printed material is sent to the curing oven. Finally, quality control is performed, after which the product goes to packing and shipping.
Embroidery
The embroidery process also requires graphic preparation – it must be adapted for production. In a special program, the needle path and stitch types are specified.
Then the machine is programmed, threads and spools are changed. The material – along with stabilizing interfacing and water-soluble film – is placed in a hoop sized for the embroidery and mounted on the machine.
The entire process must be continuously supervised – broken threads or needle breaks can occur.
After embroidery, finishing is performed: using a steamer to remove film residues, and trimming the interfacing. We also use tear-away interfacing, but due to its softness, it is not suitable for every type of embroidery – it can cause puckering or distortions.
DTF
The DTF printer also requires special attention. Levels of film, glue, inks must be monitored, as well as maintaining proper temperature and humidity.
The graphic is sent to a program that directs it to the printer – which prints the image on the film. The print is then sprinkled with glue and placed in the oven where it bonds with the base paint.
After production
Packing is the final stage in the production “life”.
Depending on the client's preference, clothes are packed loosely in boxes or individually. Individual packing may include attaching tags (hangtags), folding, packing into bags made of ecological materials (e.g., corn-based).
Only then are the products placed in boxes and sent to your companies or homes.
As you can see, production in every department is a complex and demanding process. It requires constant attention for the final result to be truly satisfying.
If you have any questions about production or need help with an order – please contact our office!
