Reprints Are Expensive: 5 Mistakes Costing You Time and Profit

Reprints are more than a headache - they’re a direct hit to your bottom line.

Whether you’re a seasoned apparel decorator or just getting started, you’ve probably had a job go sideways. A transfer that didn’t adhere. A color that came out wrong. A shirt that got ruined under the press. And before you know it, you're reprinting the entire run - burning time, money, and sometimes customer trust in the process.

The worst part? Most reprints are preventable. They’re not just the result of bad luck, they stem from small decisions that snowball into costly problems.

Let’s break down the most common root causes of failed prints and what they’re really costing your business.

1. Low-Quality Transfers

Not all transfers are created equal. I’ll say it again for the people in the back: NOT ALL TRANSFERS ARE CREATED EQUAL. Low-cost options (looking at you, bargain DTF transfers) can lead to:

➤ Poor color accuracy or dull prints
➤ Cracking, fading, or peeling after just a few washes
➤ Inconsistent adhesion or registration issues

A cheaper transfer might look okay on the surface, but if it doesn’t hold up on press or after wear, you’ll be the one footing the bill for the fix.

Tip: Professional-grade transfers like screen printed plastisol transfers offer consistent results and long-term durability, especially when backed by real customer support.

2. Inconsistent or Low-End Heat Press

A heat press is the backbone of your print quality. But when you're using a budget or unreliable machine, even the best transfers can fail. Look out for:

➤ Uneven pressure across the platen
➤ Fluctuating or inaccurate temperature readings
➤ Slow recovery time during production

The result? Peeling edges, poor adhesion, and wasted product. One misfire can easily cost more than the difference in investing in a better press.

Tip: If you’re producing regularly, upgrade to a professional-grade heat press like the ones from Insta (we’ve used them in-house for over 50 years and proudly distribute them).

3. Skipping the Test or Proofing Process

It’s easy to hit “go” on a run - especially if you’re trying to save time. But skipping a test print or not double-checking your setup is one of the easiest ways to wind up with reprints. Common pitfalls include:

➤ Incorrect spelling, sizing, or scaling
➤ Misalignment or placement issues
➤ Not testing on unique materials like tri-blends or poly-spandex

Tip: Always do a test print on the actual garment style and material. A few extra minutes upfront can save hours on the back end.

4. Operator Error or Lack of Training

Even with great equipment and transfers, mistakes happen when processes aren’t standardized. Things like:

➤ Skipping the pre-press step
➤ Misreading pressure or time settings
➤ Crooked placement or uneven layout
➤ Rushing to meet deadlines without proper setup

The good news? These are the most fixable issues with solid SOPs, training, and quality control checks in place.

5. Cheap Garments or Blanks Not Meant for Decoration

That “great deal” on wholesale blanks might cost you more than you think. Issues with low-quality or decoration-unfriendly garments include:

➤ Scorching, shrinking, or melting under heat
➤ Dye migration or ghosting on synthetic blends
➤ Poor adhesion due to slick or coated fabrics

Tip: Partner with a trusted wholesale supplier like SanMar to ensure your blanks are high-quality and built for decoration. It’s one of the easiest ways to improve print success and customer satisfaction.

So, What’s a Reprint Really Costing You?

Beyond the wasted transfers and blanks, reprints pile up hidden costs:

➤ Additional labor
➤ Missed deadlines and lost production time
➤ Rush shipping fees
➤ Refunds or discounts to frustrated clients
➤ Damaged trust or repeat business

A $2 savings on a transfer or shirt isn’t a win if it costs you a $200 reorder - or a long-term customer.

Final Thoughts: Quality is the Shortcut

Cutting corners almost always catches up with you. Instead, focus on creating a process that works every time. That means:

➤ Using professional-grade transfers
➤ Investing in the right press
➤ Testing and training consistently
➤ Sourcing quality blanks
➤ Partnering with suppliers who stand behind their products

At Howard Custom Transfers, we believe decorators shouldn’t have to choose between speed, quality, and support - you deserve all three. That’s how you eliminate reprints and protect your profit.