Behind the Scenes: How Custom Merchandise is Made (and What Clients Often Get Wrong)

Ordering custom branded merchandise can boost brand visibility and engagement, but many EU businesses struggle with production pitfalls.

According to a 2023 ASI study, 72% of marketers say unclear processes or miscommunication caused costly delays in their last merch order.

This guide reveals how custom merchandise is made - and what clients often get wrong - so you can order with confidence and avoid expensive mistakes.

Frequently Asked Questions

What are the steps in custom merchandise production?

Brief review, artwork submission, proof approval, production, quality checks and shipping.

How is my logo printed or embroidered on products?

Depending on the product and design, suppliers use screen printing, embroidery or digital printing for application.

What causes delays in custom merch orders?

Common causes include incomplete artwork, delayed approvals, unclear delivery details, and last-minute changes.

Can I visit a merch supplier or production site?

Many suppliers offer site visits or virtual tours - ask your provider for options.

How are design files prepared for printing?

Use high-resolution vector files (e.g., AI, EPS, PDF) and confirm color codes to ensure accurate reproduction.

What’s the most common production mistake clients make?

Submitting low-quality logos or skipping proof approvals, leading to errors in the final product.

How long does custom merchandise production take?

Typically 1-4 weeks, depending on order complexity, quantity and supplier capacity.

Are EU suppliers compliant with sustainability standards?

Reputable suppliers follow EU regulations and offer certifications - request documentation for assurance.

Understanding the Custom Merchandise Production Process

The journey from concept to finished product has several critical steps.
First, supplier reviews your brief and artwork.

Next, they create digital proofs and samples for approval. Once designs are finalized, production begins - using techniques like screen printing, embroidery or digital transfer. Rigorous quality checks follow before shipping to your location.

According to [Promotional Products Association International], clear communication at each stage reduces errors and streamlines delivery.

TELL ME MORE

Logo Application: Printing and Embroidery Explained

Your logo can be applied through multiple methods:

  • Screen Printing: Ideal for large, simple designs on textiles.
  • Embroidery: Adds texture and durability, perfect for apparel and hats.
  • Digital Printing: Best for complex, full-color images.

    The choice depends on your artwork, product material and intended use. High-resolution vector files ensure crisp results and minimize production issues.
WHAT ARE THE OPTIONS?

Common Causes of Production Delays

Delays often stem from incomplete artwork, slow approval cycles or last-minute changes.

EU suppliers also cite unclear delivery details as frequent bottlenecks. To avoid setbacks, finalize your design files early and confirm all order specifications up front.

According to [Sourcing Journal], proactive communication with your supplier can cut lead times by up to 30%.

YOUR UNIQUE DESIGN

Mistakes Clients Make When Ordering Branded Products

The most common errors include submitting low-quality logos, misunderstanding print areas and underestimating production timelines.

Many clients overlook sample approvals or skip reviewing proofs, which increases the risk of costly reprints.

To pre-qualify your order, always request digital or physical samples and double-check all specifications before signing off.

Site Visits and Transparency in EU Merch Production

Some suppliers offer production site tours or virtual walkthroughs, enhancing transparency and trust. This allows you to see quality standards firsthand and ask questions about processes or certifications.

If a visit isn’t possible, request detailed production documentation and photos to ensure your merchandise meets your. standards.

WHAT IS THE PRICE?

What Now?

Ready to simplify your next custom merch order?

Explore fast, reliable and fully transparent production solutions tailored for EU-based companies and events.

👉 Book your FREE consultation today or:

ADAM WROBEL (OWNER)

AHEAD PROD.

+420 727 944 046
info@aheadprod.com

LET'S MAKE YOUR BRAND VISIBLE!