EIGHT PRINT SHOP GROWTH MOVES

Medium to large custom-apparel decorators may have noticed that more customers want smaller, more frequent orders, without compromising on turnaround times. This growing demand for speed and flexibility is driving the rise of print-on-demand (POD) in the printing industry. However, meeting those expectations at scale requires the right automation. With the right software and systems in place, decorators can turn low-quantity orders into high-margin opportunities. In other words, tapping into new markets without overwhelming production teams.

It is important to remember that POD does not always mean a single shirt. POD simply means producing items as they are ordered, regardless of quantity. Whether it is one piece or 1,000, the goal is the same. The order needs to be decorated and delivered at speed. Many shops use POD workflows to fulfil large orders quickly. This is especially the case when clients expect near-instant delivery without the delays of traditional bulk production timelines.

Decorators across the country are adopting smarter, more scalable strategies. From launching always-open online stores to automating multi-step workflows and combining POD with inventory fulfilment. These eight, real-world growth moves show how operations can be streamlined, manual tasks reduced and businesses can grow. This is true for both a large production facility or one that is just getting started.

US Colorworks – a high-volume contract shop in Monroe, NC, US – had long considered adding POD. However, the company was unable to find a way to do it profitably within a bulk-focused operation. The solution came through implementing an automated, end-to-end system that removed guesswork and minimised touch points.

Owner Rodney McDonald says, “Every part of the process – from order intake to decoration and shipping – has to flow continuously without operators making micro-decisions.” He explains, “If you have to stop and think, you’ve lost money.”

US Colorworks shifted to a system that handles purchasing, batching and routing automatically. As a result, it now processes 3,000–5,000 POD orders daily as part of the company’s 30,000-unit daily output. McDonald comments, “It’s become a repeatable process that fits our shop model and protects our margins.”

“The key is finding a system that connects storefronts with fulfilment partners”

One of the biggest challenges for high-output print shops is maintaining quality control (QC) across multiple decoration methods. US Colorworks addressed this by deploying a visual QC system built into its production workflow. McDonald explains, “Operators see real-time instructions on screen, rather than relying on paper reports or tribal knowledge. It is a systematised way to ensure consistency.”

This scalable approach to QC has helped the shop outperform vendor benchmarks, even with demanding enterprise clients. McDonald goes on to say, “It lets us maintain high quality as we grow, which is something reports alone can’t manage.”

Traditional open/close online stores often create logistical headaches for decorators. This is especially true when minimums or bulk ordering constraints slow things down. Shops that shift to a fulfilment model, supporting single-item orders, can say ‘yes’ to more opportunities and reduce turnaround time.

By automating fulfilment for even small runs, shops can offer 24/7 e-commerce stores with no minimums. This opens the door to schools, teams and corporate clients who want flexible options and immediate delivery. The result is less delay, more sales and fewer missed opportunities due to order thresholds.

Print shops often hesitate to add hard goods, such as mugs or water bottles, due to inventory or decoration limitations. But access to outsourced decoration services or vetted supplier networks makes this possible. Print shops can offer these items without taking on the burden of stocking or fulfilling them in-house.

This approach allows shops to expand into corporate gifting and small-batch promo items. Customers are offered more without increasing overheads. Whether a customer wants five engraved tumblers or a mix of items in a single store, shops can deliver without worrying about hitting minimums.

“Print shops seeing the most growth have built systems that let them scale smarter, not harder”

As shops grow, so does the complexity of workflows. Without a centralised order-management system, it is easy for items to get lost or delayed. Top Shelf Printers in Colorado, US, solved this problem by transitioning from a homegrown system to an automated, QR code-based workflow.

Each production step – from receiving to decoration to shipping – is now part of a scan-based process that enables 100% visibility. Dan Freismuth, Owner, says, “We can track each item in real time and resolve any delays before they become problems.” 

With consistent instructions and automated checks, the team scaled from 6,000–25,000 units a month. Freismuth adds, “It feels like we’re running a well-oiled machine – and we know we can grow from here.”

It is not necessary to own production equipment to run a successful merchandise programme. Shops using third-party decorators or drop-ship partners can offer fully managed stores without producing items themselves. Freismuth says this has become a game changer. “You can pitch a large account, build them a store and outsource the rest. It works whether you’re a side hustle or a full-scale shop.”

The key is finding a system that connects storefronts with fulfilment partners. It needs to remove the barriers to entry and let even small players deliver big-league service.

Some clients want to sell excess inventory fast. Instead of letting gear sit in boxes, shops, such as Shirt Co in Missouri, US, build online stores that turn stock into ready-to-ship product. Often with real-time shipping, once orders are placed. Owner, Connor McDonnell comments, “It helps clients move existing inventory while giving new team members the ability to buy their gear at any time.”

This model is especially useful for venues such as fire stations, unions or clubs that already have gear but need a better system for distributing it.

Many shops offer both warehoused inventory and POD services. However, fulfilling mixed orders is often clunky. Using software that integrates with warehouse management systems (WMS) allows orders to be held until all items are ready. They can then be packed and shipped together.

This strategy helps to reduce split shipments, cuts costs and improves customer experience. For companies offering both services, consolidation can be the difference between a profitable operation and a logistical headache.

The common thread across all these moves is automation. Whether managing orders, routing production or tracking inventory, print shops seeing the most growth have built systems that let them scale smarter, not harder.

Freismuth concludes, “You get your time back. And you’re not buried in manual work or second-guessing every step.”

By embracing automation and scalable systems, print shops of any size can tap into new revenue streams, say ‘yes’ more often and build operations that – rather than stalling growth – support it.