MerchFactoryDirect

Screen Printing

Bulk Screen Printing.
Direct from the Manufacturer.

We're a US-based screen printing manufacturer for orders of 100,000+ units. No promo distributor, no markup on top of production cost — just the factory price, direct.

Get a Factory Quote
Large-volume automatic screen printing carousel in operation at Merch Factory Direct

Why Screen Printing at 100,000+ Units

Screen printing is the most cost-effective decoration method at volume. Setup costs — screens, separations, press time — are amortized across the run. At 100,000 units, that setup cost is a rounding error. At 1,000 units, it's a significant line item.

The economics only work in your favor if you're not also paying a distributor's margin on top. A promotional products company buying from a factory and reselling to you adds 40–60% to the production cost. At 100,000 units, that's a six-figure premium for a middleman to forward your artwork and process an invoice.

We work directly with buyers who have the volume to justify a direct manufacturer relationship. No rep commission, no distributor overhead, no margin stacked on factory pricing.

See the full cost breakdown →

What Makes High-Volume Screen Printing Different

ROQ automatic press lines
We run ROQ automatic screen printing equipment — industrial oval presses built for continuous large-volume runs, not adapted from a shop that normally runs 500-piece orders. Throughput and consistency are not comparable.
Pantone-matched color
We mix inks to PMS spec and maintain color across the entire run. Unit 1 and unit 100,000 are the same. For brand programs, this is non-negotiable.
In-house color separation
We handle color separation in-house. Files don't route through a distributor to an art department you've never talked to. Approvals go directly to our pre-press team.
Wash-durable decoration
Production inks and cure protocols spec'd for durability — critical for workwear, uniforms, and retail programs with wash-performance requirements.

Screen Printing Specifications

Minimum Order
100,000 units
Max Colors
Up to 8 spot colors
Ink Types
Plastisol, water-based, discharge
Print Locations
Standard + oversized
Garment Types
Tees, fleece, bags, accessories
Color Matching
Pantone PMS, run-to-run
Screen registration and pre-press setup for a large screen print run
Pre-press screen registration before a large production run
Pantone-matched ink mixing for large-volume screen printing color consistency
Ink mixed to Pantone spec — matched run to run

Ink Options for Large Runs

Plastisol
Best for: Workwear, uniforms, event merchandise

The industry standard for durability and opacity. Excellent wash fastness, vivid color on dark garments, and consistent performance across massive runs. Best for programs where longevity and brightness matter.

Water-Based
Best for: Retail, fashion, eco-certified programs

Softer hand feel than plastisol — the ink absorbs into the fabric rather than sitting on top. Required for programs with eco-certifications or retail buyers who specify soft-hand decoration. Works best on lighter garments.

Discharge
Best for: Premium retail, fashion-adjacent programs

Removes the dye from the garment and replaces it with a new color. Produces an ultra-soft, vintage feel with near-zero hand feel. Fabric-dependent — works on 100% cotton. Common for premium retail and concert merchandise.

Who Orders Bulk Screen Printing Direct

› Corporate merchandise & company store programs
› Concert tour & live event merchandise
› Retail private label & branded apparel
› Political campaign merchandise
› University & college apparel programs
› Franchise & multi-location uniform programs
› Event & festival merchandise
› Nonprofit & fundraising apparel
› Sports team & fan merchandise

Related Reading

→ What Does a 100,000-Unit Screen Print Order Actually Cost? → Plastisol vs. Water-Based Ink for Large Orders → How to Prepare Artwork for Large-Scale Screen Printing → Screen Print Setup Fees Explained → Screen Printing 100,000 Shirts: What the Production Process Actually Looks Like → Contract Apparel Decorator Factory: What Large Buyers Need to Know

Ready for a factory-direct screen print quote?

100,000+ unit minimum. US-based production. No distributor between you and the press.

Get a Quote

Screen Printing Quote Request

Tell us about your order — garment type, quantity, color count, and timeline. We'll respond within one business day.

Decoration Type *

Do you need blanks sourced?

Artwork status

Don't have files ready? We offer limited design consultation for production prep. For more involved creative work, we can connect you with our preferred design partner.

We respond within one business day. Minimum order: 100,000 units total.