400,000 piece shirt order

[ebscreen]

I would never spit in someones food.

[tpitman]

so what does that guy do with his afternoon after he is done?

Slips into his sandals and shuffles down to the chaise lounge beachside under a palm while a couple of Tahitian honeys hold his beer and massage his tired, tired shoulders.

[Screened Gear]

That would take me about half a year to do.

[3Deep]

Heck I couldn't get 400K shirts in my shop let alone print them, I'm like the rest of you 1K and I'm flipping..

[Doug S]

We just finished 1335 pcs 3 color back, 1 color over the pocket and 3 colors on the pocket.  I thought we were doing something but wow 400,000 pcs, I'd have to put off all of my regulars for half a year atleast.

[TCT]

Oh ya, we do jobs like this all day.... Ya right!!!

What's the reject allowance/over under on something like that??!

[Screened Gear]

Oh ya, we do jobs like this all day.... Ya right!!!

What's the reject allowance/over under on something like that??!

Most contract shops are 1 to 2 percent spoilage, so 4,000 to 8,000 shirts of spoilage is possible...lol

[ZooCity]

Our spoilage takes a nice nose dive on larger runs that are appropriate to our presses but at the speed one would run a job in the hundreds of thousands. ...

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[LuckyFlyinROUSH]

I wanna see how big this shop is!

[Underbase37]

We help another local shop with a big order like this once ( we only did 20k prints of it over the weekend, on two presses) and the spoilage took up storage unit. Not sure what the exact number was, but I was able to get setup shirts for super cheap for a long time.

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[GoWestRob]

The logistics of it all is enough of a headache...400,000 shirts, 72 shirts a box, 25 boxes per pallet is 222 pallets!   If they were a low cost shirt at $1.75/ea you'd be at $700,000 in blank shirt cost alone.  Better have a great line of credit or hope they are drop shipping the shirts. 

Better have the entire shop proofread that shirt before starting the presses up, you don't want to go through all of that trouble to print thousands of TuloWIZki shirts -
http://espn.go.com/mlb/story/_/id/11269809/colorado-rockies-misspell-troy-tulowitzki-name-giveaway-t-shirt-night

[Screen Dan]

Thank god we don't do contract work.  From all I've read about it mixed with the few times we did some Super Bowl contracts it sounds like nothing but a race to the bottom.

All said, it was an interesting question to ponder.  In May we pumped out 210k+ pieces, all getting at least a front and back.  Some getting a separate left and right sleeve.  Zip hoods and vests getting two separate left chest prints.  That's between 3.5 presses (three lines running, one press set up and always ready to go for close to zero downtime).  If we were to take the setups out of that equation (same design on all presses) or even have a feeder type in-line system (the smallest print area feeds the next line with the next largest print area design) I think we could probably do 750k or so in a month.  Maybe 1m if our operators had the same enthusiasm and mind for best/most efficient practices that us old school kids did when we ran the machines.

This is assuming two shifts, replacements screens are already up on deck at each line.

But at the cut-throat contract pricing?  I think that'd barely cover our operating expenses, even at the top level of efficiency possible.  I think we'll stick to our in-house printing for retail and wholesale customers.

Fascinating exercise though.

[TCT]

The logistics of it all is enough of a headache...400,000 shirts, 72 shirts a box, 25 boxes per pallet is 222 pallets!   

The Logistics are what I first thought of as well, more in the lines of how that many shirts would drown us in our small space!

[royster13]

Oh ya, we do jobs like this all day.... Ya right!!!

What's the reject allowance/over under on something like that??!

Most contract shops are 1 to 2 percent spoilage, so 4,000 to 8,000 shirts of spoilage is possible...lol

I doubt a shop that wants steady work from a  client would ever spoil 8,000 shirts.....In real life most contract printer rarely spoil that many shirts and if they do they often replace them before the bother their clients...And with quite a few "one stop shops" it is not much of an issue....

[jvanick]

When we did the 35k hoodies job, we ended up with 20 (twenty) rejects due to printing.

And about 10k pcs that we would have rejected due to mid sew... lol.