What Does a 100,000 Unit Screen Print Order Actually Cost?
A realistic breakdown of what a 100,000-unit screen print order costs — including blanks, decoration, freight, and what you're really paying when you go through a distributor vs. direct.
One of the most common questions we get is some version of: “What does a [large number] of screen printed shirts actually cost?” The answer involves more variables than most buyers expect, and it’s often dramatically different depending on whether you’re getting a direct quote or a distributor quote.
Let’s break it down honestly.
The Variables That Drive Screen Print Cost
A screen print order at 100,000 units doesn’t have a single price. It has a price based on a combination of factors:
1. The blank garment
This is often the largest single cost component in a large order. A basic 100% cotton tee from Gildan or Hanes might wholesale at $2.50–$4.00 per unit in large quantities. A premium ring-spun cotton tee from Bella+Canvas or Next Level might be $5.00–$8.00 or more. Fleece adds significantly more. Performance fabrics vary widely.
For 100,000 units, the choice between a $3.00 blank and a $6.00 blank is a $300,000 swing in blank cost alone.
2. Number of ink colors
Screen printing uses one screen per color. Each screen requires setup (burning, tensioning, registration). Setup cost is spread across the run, but more colors = more screens = higher setup and production cost.
- 1 color: least expensive
- 2–3 colors: moderate
- 4–6 colors: higher
- 7+ colors: most expensive (and usually evaluated against direct-to-garment or alternative methods at smaller scales)
3. Print size and location
A large front print covering 12”×14” uses more ink than a small chest print at 4”×4”. More ink coverage means slower press speed and higher ink cost per piece. Most printers price by print size ranges.
4. Number of print locations
Front only? Front + back? Add a sleeve? Each location is priced separately. A front + back print order can be significantly more than a front-only order.
5. Ink type
- Plastisol: Standard, opaque, durable. Least expensive.
- Water-based: Softer hand feel, more breathable. Somewhat more expensive.
- Discharge: Removes dye and replaces with ink — very soft hand, vintage feel. More expensive and requires appropriate fabric.
- Specialty inks (puff, foil, metallic): Premium add-ons.
A Sample Cost Breakdown: 100,000 Unit Order
Here’s a realistic illustration for a common order profile: 100,000 standard cotton t-shirts, 2-color front print, plastisol ink.
| Component | Per Unit | Total |
|---|---|---|
| Blank garment (standard tee) | $3.25 | $325,000 |
| Screen printing (2 colors, front) | $1.60 | $1100,000 |
| Screen setup (one-time) | — | $400 |
| Quality control / sorting | $0.10 | $10,000 |
| Packing (bulk) | $0.05 | $5,000 |
| Direct total | ~$5.00 | ~$500,400 |
Now add a distributor’s typical margin:
| Per Unit | Total | |
|---|---|---|
| Factory total | $5.00 | $500,400 |
| Distributor markup (45%) | $2.25 | $225,180 |
| Through distributor | ~$7.25 | ~$725,580 |
The distributor is adding $225,000 to the cost of this order.
These are illustrative numbers. The actual figures for your order will depend on your specific garment selection, design complexity, and market conditions. But the structure is consistent: the markup is a fixed percentage applied to a large number, producing a large absolute cost.
What Changes at Different Quantity Points
Screen printing has strong volume pricing. Here’s how decoration cost per unit typically changes as quantity scales:
| Quantity | Approx. Decoration Cost (2-color, front) |
|---|---|
| 10,000 units | $2.50–$3.50 per piece |
| 25,000 units | $2.00–$2.75 per piece |
| 50,000 units | $1.75–$2.25 per piece |
| 100,000 units | $1.50–$2.00 per piece |
| 250,000 units | $1.25–$1.75 per piece |
Illustrative estimates. Actual pricing varies significantly based on design, garment, and supplier.
The setup cost (burning screens, etc.) is the same whether you’re printing 1,000 or 100,000 units. At 100,000 units, that setup is a fraction of a cent per piece. At 1,000 units, it’s a meaningful portion of the decoration cost.
Hidden Costs to Watch For
When comparing quotes, look carefully for:
Art charges: Some distributors charge separately for art handling that factories often include in setup.
Change fees: Changes to approved art after pre-production approval can be expensive.
Overage policies: Most manufacturers produce with a +/- 2–5% variance on final quantity. Make sure you know how overages/shortages are handled.
Freight: On large orders, freight can be significant. Make sure you’re comparing total delivered costs, not just decoration quotes.
Rush charges: Compressing timelines adds cost. A standard production timeline is always less expensive.
The Takeaway
For a 100,000-unit screen print order, the total cost is typically in the $400,000–$800,000 range depending heavily on garment selection, design complexity, and whether you’re buying direct or through a distributor.
The distributor’s markup at that volume — often $150,000–$250,000 on a mid-range order — is the most actionable cost to reduce. At 100,000 units, that margin is large enough to justify the overhead of a direct manufacturing relationship.
Merch Factory Direct offers factory-direct pricing on screen print and embroidery orders of 100,000 units or more. For a breakdown of how setup costs work, see screen print setup fees explained, or request a quote to see actual pricing for your specific order.