PRECISION, POWER AND DTG PRINTING

Freckles began as a modest, full-service, embellishment shop and has evolved into a multi-million-dollar business. Rather than chasing trends, Freckles has focused on mastering tools that will ensure its success into the future. A strategic alliance with M&R Printing is at the core of that transformation.

Before M&R’s Polaris S4 direct-to-garment (DTG) platform came into play, Freckles found themselves hitting a ceiling. Like many growing operations, the company was constrained by screen-production inefficiencies, limited colour flexibility and a costly lag on short-run jobs.

The team explains, “Shooting, exposing and cleaning each screen slowed us down.” Adding, “We had the talent and the client demand, but our equipment couldn’t keep pace.”

“Freckles needed a solution that could match its ambition”

Freckles’ offerings span nearly every printing medium. These range from embroidery and dye sublimation to laser engraving, direct-to-film (DTF) and large-format signage. 

Gerry Rogers, Founder, says, “We listen first. Then we execute at scale, across platforms and on deadline.”

The versatility that kept Freckles ahead, also exposed gaps in its process. As job complexity increased and turnaround windows tightened, its legacy systems began to show strain. Freckles needed a solution that could match its ambition to handle speed, detail and unpredictability at scale. That search led them to M&R’s Polaris.

Everything changed when Freckles encountered the Polaris S4 – a DTG system engineered for precision, colour accuracy and speed. At a live M&R Printing showcase event, the Freckles team saw it in action for the first time.

Rogers recalls, “It laid white ink, flashed it, then seamlessly laid colour.” He continues, “It was like watching the future print itself.”

The timing was critical. When COVID-19 disrupted production around the globe, Freckles waited for an opening to place an order. That opportunity came when another shop backed out of a Polaris order.

“We jumped on it without hesitation,” Rogers says. “That single decision changed the direction of our business.”

Bringing in the Polaris was more than just a purchase. It was also a commitment to rethinking workflow. Freckles retooled its process, retrained its team and reimagined how fast, flexible DTG printing could serve as a competitive edge. As well as solving old problems, it opened the door to a new scale of opportunity.

Today, Freckles operates two S4 Polaris systems, turning what was once a bottleneck into a growth engine. Its production speed has accelerated exponentially. Jobs that used to take days now move in hours, without compromising on quality.

AI-generated designs, intricate graphics and multi-substrate jobs are handled effortlessly. Rogers states, “Our wash tests are consistent. The print fidelity is unbeatable. And the S4 lets us produce on nearly any substrate with confidence.”

The results speak for themselves. Freckles has expanded its reach across industries, turning heads and closing deals with high-profile partners. In one standout example, Freckles executed a live-streamed, design-to-ship initiative for a national brand. It delivered the full order within 48 hours. “We designed live, printed live and shipped the same week,” Rogers says. He continues, “That’s not just production. That’s positioning.”

“That single decision changed the direction of our business”

However, the real strength of this transformation has been the partnership behind it. As the machines powered faster output, the support behind them powered confidence and growth.

Rogers emphasises, “When something wasn’t right, M&R listened and made it right. That built trust.” The owner goes on to say, “Today, the machine runs like a dream and our business is stronger because of it.”

That trust has turned into scale. Freckles now employs 50 people and generates over €9.4 million ($11 million) in annual revenue. 
It serves a customer base ranging from local non-profits to universities and Fortune 500 brands. 

Rogers says, without hesitation, “If I had the floor space, I’d order a third Polaris today, because when we run it right, nobody can touch us.”

As Freckles looks ahead, the focus is clear – push deeper into rapid-turn programmes, elevate creative output and continue reshaping how brands view embellishment. “Technology gives you control,” Rogers explains. “And when you control production, you control the market.”

There is a crowded field of decorators chasing bulk orders and race-to-the-bottom pricing. Freckles has built something else entirely – a high-output, multi-platform creative engine powered by technology, backed by trust.

In the printing industry, power favours the prepared and the partnered. Freckles offers a blueprint for print shops ready to grow beyond capacity and into scalable, high-margin production. M&R Printing has been its launchpad.