It happens to almost everyone who reorders. The first run of shirts looked perfect. Three months later the second batch arrives and the navy looks a touch darker, or the red leans a little orange. Nobody made a mistake. Here is why it happens, and how to make your reorder match every time.
Why a reorder can look slightly different
Three things move, and only one of them is in our hands.
- Garment dye lots. Blank shirts are dyed in batches. A navy tee from March and a navy tee from September can differ by a shade, even with the same style number from the same maker.
- Ink mixing. Plastisol is mixed to a Pantone formula. When we keep your formula on file, the ink match is tight. Mix it fresh from a screenshot of a color on your phone and it will not be.
- Fabric and cure. A ring-spun cotton tee and a tri-blend take ink differently. Same artwork, same ink, a slightly different look.
| What changes | Who controls it | How to keep it consistent |
|---|---|---|
| Shirt dye lot | The blank manufacturer | Order enough for the season in one go |
| Ink color | Us | Give us the Pantone number and we save the formula |
| Garment style swap | You | Reorder the exact same brand and style number |
| Embroidery thread | Us | We log thread colors and the stitch file for repeat runs |
Screen printing reorders: the Pantone rule
Your brand red is not just red. It is a Pantone number, and that number is the thing that makes your reprint match. If you have a brand guide, send us the numbers. If you do not, tell us on the first order that you plan to reorder, and we will record the mixed formula alongside your screens.
Embroidery reorders are the easiest
Once your logo is digitized, the stitch file is saved. Same file, same thread numbers, same result. The only variable left is the garment color, so keep the style and color name written down.
DTF and digital reorders
Digital printing reads colors from a file, so repeat orders match closely as long as the artwork file and the garment are the same. Dark and light garments can still shift how a color reads, which is normal physics, not a defect.
A simple reorder checklist
- Keep your order number or the name of the first job.
- Write down the garment brand, style number and color name.
- Save the final approved artwork file, not a screenshot.
- Order a little over your count so late hires do not force a mismatched batch.
- If a perfect match matters, ask for a sample from the new batch before we print everything.
If you ever do receive a batch that looks off to you, tell us right away with a photo in daylight. We would rather look at it together than have you wear it in doubt.
Need more of what you ordered last time?
Tell us the job and we will pull up your files and colors. Visit us at 11642 Knott Street Suite E-19, Garden Grove, or call.
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