The most common question Washington businesses ask before placing a screen printing order is simple: “How many shirts do I need to order?” The short answer is 24 pieces per design at NW Custom Apparel. But understanding why that number exists — and what happens to your cost when you order 12, 48, or 144 pieces — will help you make a smarter decision for your crew, your budget, and your timeline.
This guide covers screen printing minimum order quantities from a production standpoint, not a sales standpoint. After 40+ years decorating apparel for Washington state construction crews, HVAC companies, schools, and corporate teams, we know exactly what drives these numbers. No guesswork here.
What Is a Screen Printing Minimum Order Quantity?
A screen printing minimum order quantity (MOQ) is the fewest number of garments a print shop will run on a single press setup for one design. At NW Custom Apparel, that number is 24 pieces per design.
This minimum is not arbitrary. It exists because screen printing is a fixed-cost production method. Before the first shirt is printed, a significant amount of time, material, and labor is already spent, and that cost stays the same whether you order 10 shirts or 500.
Here is what happens before your first piece comes off the press:
Art preparation. Your logo or design gets separated into individual color layers. Each color in your design becomes its own film positive, a transparency used to burn the screen.
Screen burning. Each color requires its own mesh screen. The screen gets coated with light-sensitive emulsion, the film positive is placed on top, and UV light hardens the emulsion everywhere except where your design is. A 3-color logo means 3 separate screens burned and prepared.
Screen registration. Every screen is loaded onto the press and precisely aligned so each ink color lands exactly where it should. On a manual press, this is done by hand. On an automatic press, registration is faster but still requires careful setup and test prints.
Test prints. Before the full run begins, test prints confirm color accuracy, registration alignment, and ink coverage. These test prints are consumed during setup, they do not count toward your order.
A typical screen setup runs $25 to $45 per screen per color. A 3-color design means $75 to $135 in screen charges alone before a single finished shirt comes off the press. Add art preparation, ink mixing, press time, and final curing, and the fixed cost for one design setup often reaches $150 to $250 total.
When you divide that fixed cost across 144 shirts, it adds roughly $1–$2 per shirt. When you divide it across 12 shirts, it adds $12–$20 per shirt just for setup, before the garment cost or per-piece print labor.
That math is why minimum orders exist.
Standard Screen Printing Minimums in the USA
Minimum order quantities vary across print shops based on their equipment, overhead, and client base. Here is what the industry looks like:
| Minimum Quantity | Who Typically Sets This |
|---|---|
| 12 pieces | Small local shops serving schools, teams, startups |
| 24 pieces | Most mid-size shops; standard for multi-color designs |
| 48–72 pieces | High-volume shops with automatic presses, optimized for corporate orders |
| 100+ pieces | Contract and wholesale printers |
A 1-color design can meet a minimum of 10 pieces because it can be run by hand. A 7- or 8-color design requires an automatic press and typically requires a minimum of 50 pieces.
At NW Custom Apparel, our minimum is 24 pieces per design. This covers the setup cost on our equipment while keeping your per-piece cost at a level that makes sense for Washington businesses ordering 24–500 pieces at a time. See our guide on DTG printing for orders below the screen printing minimum threshold.
How Does Number of Colors Affect Your Minimum?
Color count is the single biggest variable in screen printing minimum orders. Every color in your design requires a separate screen, a separate setup step, and a separate pass through the press. More colors means higher fixed costs, which means a higher minimum to break even.
Here is how color count maps to typical minimums:
| Design Colors | Typical MOQ |
|---|---|
| 1 color | 12–24 pieces |
| 2–3 colors | 24 pieces |
| 4–6 colors | 24–48 pieces |
| 7+ colors | 50+ pieces |
One detail many buyers miss: printing on dark-colored garments adds one more color to your count. Dark shirts require a white underbase (a base layer of white ink printed first), so the design colors appear vibrant against the dark fabric. All colored garments require an underlay charged as one additional color, and flashing is required on all colored garments. A 3-color design on a black shirt effectively becomes a 4-color job.
For Washington construction crews ordering hi-vis shirts with logo printing, this matters. Orange and yellow hi-vis fabrics often require ink adjustments to maintain brand color accuracy, which affects setup complexity. Source
The NW 3-Factor Minimum Selector
After 40+ years of running screen printing orders for Washington state businesses, Erik Mickelson developed a simple decision framework for determining the right quantity tier for your order. Three factors drive your minimum and your per-piece price:
- Design complexity (color count). Every color added increases setup cost. For most Washington workwear orders (a left-chest logo in 1–2 colors), the minimum stays at 24 pieces with straightforward pricing.
- Garment type. Standard t-shirts, polos, and hoodies all load onto the press similarly. Hi-vis safety shirts, structured work jackets, and heavyweight canvas workwear require different press setup. Specialty garments sometimes increase the effective minimum because setup time per piece is higher.
- Order frequency. If you are ordering quarterly for crew turnover, a higher initial quantity almost always wins on cost. Ordering 48 instead of 24 on the first run typically reduces per-piece cost by 15–30% and eliminates a full setup fee on the reorder.
Use this framework before you request a quote. It will tell you which quantity tier makes financial sense before any numbers are on the table. See our guide on DTG printing for orders below the screen printing minimum threshold.
How Does Cost Per Piece Change With Quantity?
This is the main question for every Washington business manager ordering custom workwear. Setup cost is fixed. Per-piece price drops as you spread that fixed cost across more garments.
Here is a cost breakdown example for a 2-color front logo on a standard t-shirt:
| Order Quantity | Setup Cost | Per-Piece Print Cost | Garment Cost | Approx. Total Per Piece |
|---|---|---|---|---|
| 12 pieces | $80 (2 screens) | $3.50 | $5.00 | ~$16.80 |
| 24 pieces | $80 | $3.00 | $5.00 | ~$11.33 |
| 48 pieces | $80 | $2.50 | $4.75 | ~$9.92 |
| 72 pieces | $80 | $2.00 | $4.50 | ~$8.61 |
| 144 pieces | $80 | $1.75 | $4.25 | ~$7.81 |
Numbers are illustrative based on standard 2-color print. Actual pricing depends on design, garment selection, and order details. Contact NW Custom Apparel for a quote.
The takeaway: doubling your order from 24 to 48 pieces reduces per-piece cost by roughly 12–15%. Doubling again to 144 pieces brings another 10–15% reduction. The biggest savings jump happens between 12 and 48 pieces, where setup cost amortization has the most impact.
What Is a Gang Run and Can It Help Your Order?
A gang run combines multiple small orders onto the same press setup when they share the same ink colors and garment color. Some shops combine multiple small orders onto the same press run if they share the same garment color and ink colors, which reduces per-piece costs for everyone involved.
At NW Custom Apparel, gang runs are evaluated on a case-by-case basis. If your order is close to a minimum threshold and you have flexibility on timing, ask your customer service rep whether a gang run option is available for your job.
Gang runs are more common for simple 1-color designs on standard garment colors. Complex or specialty jobs rarely qualify.
Options If You Need Fewer Than 24 Pieces
Screen printing is the most cost-effective decoration method for orders of 24 pieces or more. For orders below that threshold, two alternatives make more sense.
Direct to Garment printing (DTG). DTG printing uses an industrial inkjet process that prints directly onto the fabric. There is no screen setup, no film burning, and no registration, which means no minimum order. DTG is ideal for 1–23 pieces, complex multi-color designs, and photo-realistic artwork. The tradeoff is per-piece cost: DTG is more expensive per shirt than screen printing at 24+ pieces. Learn more about DTG printing for small-quantity orders.
Direct to Film printing (DTF). DTF printing produces a heat-transfer film that is pressed onto the garment. Like DTG, it requires no minimum. DTF works on virtually any fabric type, including polyester blends and nylon — fabrics that DTG handles poorly. For Washington HVAC crews or safety gear made from moisture-wicking polyester, DTF is often the right call for small runs. Learn more about DTF printing for under-minimum runs.
Here is a direct comparison for buyers deciding between methods:
| Method | Minimum Order | Best For | Cost Per Piece (Small Run) |
|---|---|---|---|
| Screen printing | 24 pieces | 24–500+ pieces, 1–6 colors, cotton/blends | Lowest at volume |
| DTG printing | No minimum | Under 24 pieces, complex artwork, cotton | Higher per piece |
| DTF printing | No minimum | Under 24 pieces, polyester/mixed fabrics | Moderate per piece |
See our detailed comparison between DTG, DTF, and Screen Printing to decide which is right for your order.
How to Work Within the Screen Printing Minimum If You Are Close
If your order is at 18 or 20 pieces and the minimum is 24, a few strategies work:
Order up to the minimum. The extra 4–6 pieces cost far less than the alternative. Use them for new hires, replacements, or giveaways. The marginal cost of 4 additional shirts is a fraction of what a separate small-run order would cost later.
Simplify your design. A 4-color design with a 48-piece minimum becomes a 2-color design with a 24-piece minimum if you simplify the artwork. Ask your NW Custom Apparel rep whether a simplified version of your logo achieves the same brand recognition at a lower setup cost.
Combine uses. If your company needs both work shirts and volunteer shirts at the same event, combine them into one order as long as they share the same design and ink colors. Minimums apply to the total number of pieces per design, not per size. An order of 3 Small, 4 Medium, 3 Large, and 2 XL is a 12-piece order. You do not need 12 of each size.
What to Expect for Large Runs (72 Pieces and Up)
For Washington businesses ordering 72 pieces or more — construction companies outfitting full crews, school athletics programs, corporate uniform programs — the economics of screen printing work strongly in your favor.
According to industry production standards, automatic screen printing presses produce 600–1,200 shirts per hour once setup is complete. Large runs allow the press to run continuously after setup, which is where screen printing becomes dramatically more cost-efficient than any other method.
At the 72-piece threshold and above, you also qualify for:
- Lower per-piece pricing from garment suppliers (bulk blank pricing from distributors like SanMar)
- Priority production scheduling at NW Custom Apparel
- Potential for multi-location printing (front logo + back text) at reduced additional cost per location
For Washington businesses running annual uniform programs like outfitting 50–200 employees per cycle, the long-term strategy is to set up your artwork once, store the screens, and reorder at the same setup cost on subsequent runs. Ask about our screen storage policy when you place your first order.
Screen Printing for Hi-Vis and Safety Workwear in Washington State
Washington state construction companies, road crews, and utility teams ordering hi-vis safety shirts face one additional consideration that most screen printing guides ignore: ANSI/ISEA 107 compliance.
High-visibility safety apparel used on Washington job sites must meet ANSI/ISEA 107-2020 performance class requirements. Class 2 garments require at minimum 755 square inches of fluorescent background material and 201 square inches of retroreflective tape. Class 3 garments require 1,240 square inches of fluorescent background and 310 square inches of retroreflective tape.
When adding a logo or text to a compliant hi-vis garment, the print placement must not cover retroreflective strips or reduce the compliant reflective surface area below the class threshold. This is a real constraint that affects where your logo can be placed on the garment.
NW Custom Apparel has decorated ANSI-compliant hi-vis shirts for Washington construction and HVAC crews for decades. Our team reviews placement against compliance requirements before production. See our custom hi-vis safety shirts with logo printing for garment options that meet ANSI/ISEA 107-2020 requirements.
Frequently Asked Questions
NW Custom Apparel’s screen printing minimum is 24 pieces per design. This applies to most standard orders. Contact us for specialty garments, which may have different minimums based on press setup requirements.
Yes. Size mixing is allowed within a single order as long as the design, ink colors, and print placement remain the same. An order of 6 Small, 8 Medium, 6 Large, and 4 XL counts as a 24-piece order.
If your screens are stored from a previous order, the setup fee on a reorder is reduced or eliminated. Ask your NW Custom Apparel rep about our screen storage policy when placing your first order.
Orders under 24 pieces are better suited for DTG or DTF printing, both of which have no minimum at NW Custom Apparel. DTG works best for cotton garments with complex artwork. DTF works on a wider range of fabric types including polyester workwear.
Each color in your design requires a separate screen setup. More colors increases the fixed cost of the job, which typically raises the minimum quantity. A 1-color design has a lower effective threshold than a 6-color design at most print shops.
NW Custom Apparel offers rush t-shirt printing in Washington with 5–7 day turnaround on qualifying orders. Rush minimums and availability depend on current production scheduling.
Get a Quote for Your Washington Screen Printing Order
NW Custom Apparel has served Washington state businesses, construction crews, schools, and organizations with custom screen printing services since 1977. We print from our Milton, WA facility with turnaround options for both standard and rush orders, shipping statewide and nationwide.
For orders of 24–500 pieces: request a screen printing quote using our contact form. Include your piece count, design color count, and garment preference.
For orders under 24 pieces: ask about DTG and DTF printing options with no minimum requirements.
