Is Screen Printing Cheaper in Bulk? Here’s What to Know

If you’ve ever ordered custom t-shirts, hoodies, or promotional apparel, you’ve probably noticed that screen printing costs drop dramatically when you order in bulk. But why does this happen? Is it really cheaper in the long run, and what factors determine the final price per garment?

This article breaks down how screen printing pricing works, why larger quantities lead to savings, and what small businesses, teams, or event organizers should consider before placing a bulk order.

Let’s dive into the economics behind one of the most popular printing techniques in the apparel industry.

Understanding How Screen Printing Works

Screen printing is a traditional yet highly effective method for decorating apparel. The process involves creating a separate stencil (or screen) for each color in your design. Ink is pushed through the mesh screen onto the fabric and then heat-cured for durability.

Because each color requires its own screen, the setup process is time-consuming and labor-intensive, especially for smaller orders. However, once the screens are ready, printing multiple garments becomes much faster and more cost-efficient.

Key Components of the Process:

1. Artwork preparation: Digitizing and separating colors for each screen.
   
   

2. Screen creation: Coating, exposing, and washing out the stencil.
   
   

3. Ink mixing and setup: Preparing colors and aligning screens.
   
   

4. Printing and curing: Applying the ink and heat-setting it.
   
   

These steps make up the bulk of the production cost which means that as your order size increases, the setup cost is spread across more units, significantly lowering the per-item price.

Why Screen Printing Gets Cheaper in Bulk

The main reason screen printing is more affordable in larger quantities is the economy of scale.

When a printer sets up a job, much of the work (and cost) happens before the first shirt is ever printed. Once that initial setup is done, each additional print requires minimal time and resources.

Here’s how the savings work:

1. Setup Costs Stay the Same

The screens, inks, and registration process take the same amount of effort whether you’re printing 10 shirts or 500. Larger orders spread that cost out, reducing the price per shirt.

2. Efficiency Increases with Quantity

Once the press is running, printing more garments takes very little additional effort. Modern automatic presses can produce hundreds of shirts per hour.

3. Bulk Material Discounts

Printers often get discounts on blank garments and inks when buying in bulk, and these savings are typically passed on to the customer.

4. Lower Labor Cost Per Unit

Printing one shirt takes nearly as much setup time as printing 100, but the labor cost per shirt decreases dramatically with volume.

Example:

If setup costs total $100 and each shirt costs $5 in materials and labor:

• 10 shirts would cost $15 each.
  
  

• 100 shirts might cost $6 each.
  
  

• 500 shirts could drop below $5 each.
  
  

This is why screen printing is the go-to method for bulk apparel orders.

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Typical Pricing Tiers for Screen Printing

While exact prices vary between companies, most printers offer tiered pricing based on quantity.

Here’s a general breakdown (for a one-color print on cotton t-shirts):

These numbers are just examples, but they illustrate how each additional unit lowers your per-piece cost.

Factors That Influence Bulk Pricing

1. Number of Colors in the Design

Each color requires its own screen, which means additional setup time and cost.

• 1–2 colors: Most affordable for bulk production.
  
  

• 3–5 colors: Medium range; higher setup cost but still efficient for large runs.
  
  

• 6+ colors: More expensive, often better for smaller quantities or digital printing.
  
  

2. Number of Print Locations

A front-only design costs less than printing on both the front and back.
Adding sleeve prints or inside labels increases complexity and time.

3. Garment Type and Material

Basic cotton t-shirts are cheaper to print than hoodies, jackets, or specialty fabrics.
Polyester and blends may require special inks and curing temperatures.

4. Ink Type

• Standard plastisol inks: Most affordable and durable.
  
  

• Water-based or discharge inks: Softer feel but slightly higher cost.
  
  

• Specialty inks: Metallic, puff, or glow-in-the-dark inks add to the price.
  
  

5. Turnaround Time

Rush orders often come with additional fees. Bulk orders scheduled in advance benefit from more efficient workflow and better pricing.

The Cost Advantage for Businesses and Organizations

Bulk screen printing is particularly advantageous for businesses, schools, events, and sports teams that need uniform branding.

Key Benefits:

• Lower unit cost: Makes it easier to resell at a profit.
  
  

• Consistent branding: All garments look identical, creating a professional image.
  
  

• Inventory flexibility: You can stock extras for future events or sales.
  
  

• Simplified reorders: Once screens are made, reprints are faster and cheaper.
  
  

For example, a restaurant ordering 200 branded t-shirts for staff uniforms pays less per shirt than ordering in small batches throughout the year.

Bulk Orders vs. Small Runs: Which Is Right for You?

While bulk orders clearly save money, smaller runs might be more practical in some situations.

Choose Bulk Orders If:

• You have an established brand or event with predictable demand.
  
  

• You plan to sell or distribute apparel over time.
  
  

• You want to maximize your budget per unit.
  
  

Choose Small Runs If:

• You’re testing a new design or market.
  
  

• You have limited storage space.
  
  

• You prefer to offer limited-edition or seasonal products.
  
  

Some businesses use small runs for testing, then move to bulk printing once they confirm which designs sell best.

How to Maximize Savings on Bulk Screen Printing

If you’re planning a bulk order, there are several strategies to stretch your budget even further.

1. Simplify Your Design

Stick to one or two ink colors to minimize setup fees.

2. Print on Common Garment Types

Choose popular shirt styles that printers keep in stock. They’re usually cheaper and faster to produce.

3. Consolidate Your Orders

Instead of printing 50 shirts now and 50 later, print all 100 at once to get the bulk discount.

4. Plan Ahead

Avoid rush jobs. Giving your printer time to schedule your project allows for better pricing and quality control.

5. Work With a Local Partner

A local print shop can save you on shipping, provide samples, and help you choose the right garments and print options for your budget.

Quality Considerations in Bulk Printing

Low cost shouldn’t mean low quality. A professional printer will ensure your large order maintains consistent color, alignment, and curing.

Ask your printing partner to:

• Provide digital proofs before production.
  
  

• Run a sample print to confirm accuracy.
  
  

• Inspect prints throughout the job for uniformity.
  
  

Consistent quality across hundreds of garments reflects directly on your brand.

Focus on Colortex Ottawa: Your Local Screen Printing Experts

When it comes to bulk screen printing in Ottawa, few companies match the experience and reliability of Colortex Screen Printing & Embroidery.

Why Colortex Is the Right Choice:

• Bulk Pricing Advantage: Colortex specializes in large orders for retailers, promotional clients, and small businesses, offering competitive per-unit rates.
  
  

• Full-Service Capabilities: They provide screen printing, embroidery, and sublimation, making them a one-stop solution for apparel decoration.
  
  

• Professional Equipment: High-quality presses ensure consistent results, even in high-volume production.
  
  

• Local and Accessible: Based in Ottawa, Colortex offers personalized customer support and fast turnaround for Canadian businesses.
  
  

• Versatile Product Range: From t-shirts and hoodies to caps and accessories, they can handle all your printing needs in-house.
  
  

Whether you’re outfitting a corporate team, producing branded merchandise, or stocking your retail shelves, Colortex Ottawa delivers affordable bulk printing without compromising quality.

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Conclusion: Bulk Printing Is Smart Business

Screen printing truly shines when you print in bulk. The more garments you produce, the more you save per piece. By understanding setup costs, choosing efficient designs, and partnering with a trusted local printer, you can achieve professional-quality results that fit your budget.

For businesses and creators ready to scale their apparel production, Colortex Screen Printing & Embroidery in Ottawa offers the perfect blend of quality, affordability, and expertise to bring your designs to life at any volume.