Ready to level up your print shop? With the right equipment choices, efficient materials, and streamlined workflows, you can get big-shop results from your current setup. This quick guide shows you how to grow smarter, right where you are.
Shifting Your Mindset: ‘You Don’t Need a Warehouse to Print Big’
Consider this: Your shop layout has a direct impact on your output speed and profitability. That means a well-organized 500-square-foot shop can outperform a poorly laid-out 2,500-square-foot one. If you try to think like an assembly-line engineer and truly understand your workflow, you won’t just fill space. You’ll place your equipment and supplies in the order of your production flow.
If direct-to-film (DTF) transfers are your highest-revenue process, you might sequence your steps like this: CADLink file station, DTF printer, powder shaker/cure unit, heat press, and packing table. When you physically map out your workflow, you’ll immediately be faster than an unorganized, larger shop. Additionally, you’ll reduce chaos when jobs overlap or rush orders arrive, as well as help part-time or rotating staff stay organized.
Here’s a quick audit you can do in your shop to see if you’ve optimized your space.
1. Have you eliminated unnecessary steps?
For example:
-
Placing your DTF printer next to the heat press saves 10 to 15 minutes per batch just in walking/material handoffs.
-
Stocking the day’s blanks within reach of each station avoids constant backtracking.
2. Have you created a physical “production line”?
You can build out your flow by using tables or carts to create a visual scheme: order intake, file setup, printing, curing, pressing, finishing, and shipping. Some shops create an L- or U-shaped layout to keep equipment and stations within a few steps, thereby creating a natural job path.
You can add rolling carts stocked with film, blanks, powder, or cleaning supplies to reduce walking and maintain flexible stations. Use rolling carts as mobile command centers—one for powder refills, one for blanks and transfers—and then relocate them as needed to minimize steps and downtime.
Setting up your path reduces mixups when you’re juggling multiple small jobs. You’ll also find it’s easier to onboard new or rotating team members with less training time.
3. Have you standardized steps so you can scale without chaos?
For example, here are some ways to do it:
-
Save preset templates in your RIP software for standard placements, such as left chest and full front.
-
Use hot folders to automate standard orders, especially for repeat clients.
-
Use visual storage systems—like clear bins, labeled drawers, and color-coded film rolls, garment blanks, powder types, and shipping supplies—to make grab-and-go organization effortless for your team.
-
Group jobs by garment type, color, or design placement to avoid switching platens, temperatures, or inks. That means pressing 40 white poly tees in a row saves 30 minutes vs. constantly switching between cotton/poly blends.
These micro-systems cut decision fatigue and lost minutes every shift.
4. Have you batched similar jobs to reduce setup time?
If you’re running 20 cotton tees, then 10 polyester jackets, and then 15 canvas totes? That’s three setup changes, so if you group jobs by substrate, film type, or design style, you’ll save a lot of time. For example, batch cotton jobs first to avoid switching ink settings, press temps, or platen types.
Each material change can cost 10 to 15 minutes of downtime. Multiply that by 10 or more jobs/day, and it adds up fast. Plus, if you batch jobs, your team can see what’s coming next and avoid scrambling when they’re surprised by the next round.
5. Have you automated parts of your workflow?
For example:
-
Use RIPs with nesting, auto-scheduling, and batch file handling to eliminate manual setup.
-
Set up barcode scanning or queue-based printing from webstores. This reduces back-and-forth and error-prone manual entry.
6. Have you invested in machines that do multiple jobs or speed up steps?.
For example:
-
A dual-platen heat press doubles output without doubling space.
-
DTF roll-to-roll systems automate curing and film feeding, resulting in hours of labor reclaimed per week.
-
Print/cut and print/laminate hybrids condense two machines into one footprint, designed for tight shops.
7. Have you invested in compact machines that offer a sizeable output?
Many of the high-output and large-format printers on the market today are compact, relatively quiet, and designed to fit in smaller spaces, so you don’t need massive square footage or special ventilation. Today’s models are also more user-friendly, featuring easy setup, touchscreen controls, and quick media swaps, which reduces the need for operator training.
Pro tip: Look for compact curing units that sit right next to your printer, like Arcus' integrated setups, so you’re not walking across the room every time a transfer cures.
8. Do you track your weekly metrics so you can make better decisions?
Monitor average turnaround time, number of reprints, downtime per station, and idle time per operator, so use this data to adjust layout, shift timing, and material prep. Let’s say you learn that 70% of reprints come from file setup issues, then fix the intake process first, not the print equipment.
9. Have you optimized your team to work efficiently in your space?
For example:
-
Cross-training prevents single points of failure. So, if your only heat press operator is out, production comes to a halt. If you train everyone on your core workflows (pressing, prepping, packing), you can flex coverage as needed.
-
Make team feedback part of your weekly ops. For example, 15-minute Friday debriefs can surface problems you’re not seeing, like a specific platen always jamming or a layout causing traffic jams at peak times.
-
Gamify accuracy and speed to boost morale and output. Track jobs completed per shift, error-free streaks, or average press times. Then post a leaderboard or offer small rewards—when teams feel ownership over efficiency, they work smarter.
-
Weekly resets lead to smoother shifts. Use low-volume days to clean equipment, restock supplies, and prep hot folders or blank inventory.
In a smaller shop, every square foot should add production value. If something doesn’t reduce steps or improve speed, it’s time to rethink its placement or presence.
Start With the Right Printer to Maximize Output With Minimal Space
Smaller shops can get more bang for their buck by investing in multi-use equipment that does more with less.
Here are some things to consider:
1. A multi-use printer setup covers more product categories with fewer machines.
For example:
-
A single DTF printer can decorate a wide range of materials, including cotton, polyester, leather, and blends, eliminating the need for separate machines for each fabric type.
-
A compact UV-DTF printer allows you to produce hard goods, such as tumblers, journals, mugs, and packaging, without requiring a jig, flatbed, or heat press.
Together, they let you fulfill both apparel and promo product orders from the same square footage.
2. A DTF printer lets you print full-color textiles with faster, simpler workflows.
-
The DTF process is simple: print your transfer, add adhesive powder, and press. You save time since you don’t need to pretreat your garment, and there’s no drying time.
-
Unlike other decorating methods, DTF results in full-color, vibrant graphics on a wide range of fabrics, including cotton, polyester, blends, denim, leather, and more.
-
Compared to DTG or sublimation, DTF slashes print time, labor steps, and fabric limitations.
3. A UV-DTF printer lets you create transfers for hard goods and promo products.
-
UV-curable inks, combined with adhesive film, create instant-dry transfers that adhere to textured, curved, or irregular surfaces with only pressure.
-
These transfers adhere to glass, plastic, coated metal, wood, acrylic, and even uneven packaging, allowing one printer to accommodate a wide range of products in your lineup. You can also do small-batch or custom work that doesn’t justify a flatbed investment or time-consuming weeding.
4. Pairing DTF and UV-DTF machines means that you can offer apparel and hard goods in a compact setup.
Without relying on other printing methods, such as screen printing, DTG, or sublimation, you can fulfill apparel and promotional orders directly from your shop. You don’t need to send jobs out or expand your square footage. Investing in these two transfer printers is a powerful way to increase average order size, upsell bundles, and enter new markets without changing your shop layout.
Your DTF Film and Powder Are Part of Your Workflow, Too
The film and powder you use with your printers can also significantly impact your timing and quality. If you use cold peel film, that can slow you down over a day, since you’re adding 30 to 60 seconds per press. Multiply that cooldown time by 300 shirts, and that adds up to 2.5 to 5 hours of lost press time. Using cold peel also increases handling errors, because if you peel too soon, the design lifts or distorts.
However, if you switch to instant peel film, where you press, peel, and stack with no cooling step, you can eliminate downtime and press bottlenecks. Your operators can maintain continuous press cycles, which improves your overall time per job and reduces staff downtime. This is a massive benefit for same-day or rush turnaround shops.
Your powder quality also matters. Not all adhesives are created equal. Lower-quality formulas often cause spotty adhesion or cracked edges, flaking during washing, a grainy or gritty hand feel, and dull or cloudy prints, especially on dark garments.
On the other hand, when you switch to a higher-quality powder, you’ll get commercial-grade consistency. When you press, you’ll achieve a clean melt for full adhesion, with no cracking and color stability. Low dust also makes a safer workspace and ensures even film coverage.
What You Need for Your Small-Space In-House Setups
A high-efficiency in-house setup typically includes a DTF or UV-DTF printer, instant peel film, commercial-grade powder, a heat press or integrated curing unit, and RIP software such as CADlink for nesting and color control.
Product recommendation: The Arcus Pioneer 14 DTF Printer is a powerhouse in a compact frame, designed for high-output decorators working in tighter retail spaces. This DTF printer runs on standard 110V power, fits through a standard doorway, and doesn’t require industrial exhaust, HVAC upgrades, or chemical zones, making it ideal for smaller shops or shared spaces.
With a single-roll-fed setup, the Pioneer 14 prints vibrant, adhesive-backed transfers that adhere to a wide range of materials, including cotton, poly, leather, denim, and more, without requiring any pretreatment. Built-in anti-clog features, low consumable costs, and U.S.-based support make it a versatile workhorse that scales with your order volumes.
Product recommendation: The Arcus Monarch 24 UV-DTF Printer delivers industrial-level output in a compact, plug-and-play footprint, great for small shops expanding into hard goods. The Monarch 24 runs on standard 110V power, fits tight spaces, and pushes out up to 110 linear feet per hour using three Epson I3200 heads. With no need for a jig, heat press, or lamination, it applies vibrant, waterproof, scratch-resistant transfers to curved and textured surfaces, such as bottles, mugs, signage, and packaging, using just pressure.
The self-weeding, press-and-go workflow eliminates cutting and trimming, making it faster and more scalable than HTV or traditional UV printing. Low material costs and complete Arcus onboarding make it easy to launch or scale high-margin promo work (no flatbed required).
Product recommendation: For decorators looking to speed up production without sacrificing quality, Arcus Instant Peel Film is a game-changer. This instant peel formula eliminates the cooldown step: Just press, peel, and move on, making it ideal for fast-paced shops and stacked production runs. Available in 14" and 24" rolls, it delivers bold, durable prints on cotton, poly, blends, and leather, all without requiring a workflow overhaul.
Product recommendation: Arcus DTF White Powder Glue is designed for shops that can’t afford surprises. This adhesive delivers strong, flexible adhesion on cotton, poly, blends, and leather without cracking, stiffness, or dulling your prints. Low-dust and easy to handle, it pairs seamlessly with Arcus Instant Peel Film to streamline your workflow and ensure consistent results, even on rush orders or large team drops.
Bringing Your Transfer Production In-House
If you’re outsourcing buying transfers, you’re dealing with higher costs and a slower turnaround. Premade transfers add markup on film, powder, ink, labor, and shipping. Custom transfers often cost four to five times more per unit than in-house DTF. You also lose flexibility for rush jobs, edits, or last-minute personalization. Stock designs limit creativity, and custom orders often require hefty minimums.
Outsourcing may be suitable for hobbyists or low-volume shops, but for businesses with 20 or more orders/week, it can significantly impact profitability and slow down your turnaround. But when you start producing transfers in-house, you suddenly control the speed, quality, and margins, along with these benefits:
-
Eliminate backorders, vendor delays, or lost shipments.
-
Print orders same day or offer a 24-to-72-hour fulfillment.
-
Control the quality by setting the color profiles, adjusting the print resolution, and inspecting the output before it leaves the door.
-
Personalize names, numbers, or artwork instantly for rush jobs, 1-to-25 piece orders, last-minute personalizations, and niche custom work other shops turn down.
-
Market this speed advantage, especially to schools, teams, and event clients.
-
Enjoy a higher profit per piece, allowing you to achieve a faster ROI on your equipment.
Here’s a real-world example to consider: A small shop selling school merchandise was paying $8 per unit for outsourced custom transfers. After switching to an in-house DTF setup, the team reduced the cost per shirt to less than $2 per unit. Turnaround time dropped from four to six days to under 24 hours. The shop started offering last-minute event orders and boosted total revenue by 40% in one quarter.
Your Final Takeaway: Big-Shop Output Without the Big-Shop Overhead
In-house printing offers you the flexibility to scale. You control production, improve margins, and build loyalty by delivering fast, reliable work. The ability to say “we’ve got it” is what turns one-time customers into repeat clients. With the right setup, small shops can operate like big ones, utilizing smarter systems, without the need for sprawling square footage or excessive overhead.
Why Arcus Printers?
Plug-and-play printers, such as the Pioneer 1714 or Monarch 24, deliver industrial-level speed in a compact footprint. Paired with instant peel film and pro-grade powder, they create a streamlined, high-margin setup that scales with your business. With U.S.-based support, training, and engineered consumables, Arcus helps lean shops print big.
Visit www.arcusprinters.com to learn more.
