Table of Contents
- Primer: What This Workflow Covers and When to Use It
- Prep: Designs, Materials, Machines, and Workspace
- Setup: Hooping Choices, Thread Weight, and Test-Stitch Strategy
- Operation: Step-by-Step Production
- Quality Checks: What “Good” Looks Like
- Results & Handoff: Packaging, Pickup, and Records
- Troubleshooting & Recovery: Fast Fixes and Customer Care
- From the comments: Real-world Q&A
Video reference: “Work With Me: Behind the Scenes of a Custom Apparel Business” by Kayla's Custom Tees & More
If you run a custom apparel shop, production days can stack up fast: caps, pads, jackets, tumblers, and tees—all with different methods and pitfalls. Here’s a crisp, start-to-finish guide that mirrors a real shop day so you can move confidently from embroidery to heat work to handoff without rework.
What you’ll learn
- How to finish embroidered beanies so small text stays crisp and comfortable.
- Best practices for hooping and stitching thick items like saddle pads and Carhartt-style jackets.
- How to sublimate 4-in-1 can coolers and spot issues early.
- Screen print transfer application that stays straight, centered, and fully adhered.
- Practical quality checks, customer-service decisions, and recovery moves if products fall short.
Primer: What This Workflow Covers and When to Use It This guide walks through a typical multi-method production run: finishing 50 embroidered beanies for pickup, embroidering saddle pads, test-stitching and embroidering thick jackets, sublimating 4-in-1 can coolers, and applying screen print transfers to hoodies and t-shirts. You’ll see where to add test stitches, when to step down thread weight for small text, and how to sanity-check alignment and adhesion before items go out the door.
- When it applies: Batch finishing (beanies), bulky or structured items (saddle pads, outerwear), rigid drinkware (tumblers), and quick-turn apparel decoration (screen print transfers). magnetic hoops for embroidery machines
- Prerequisites: Digitized embroidery files, printed sublimation designs, and the screen print transfers you plan to apply.
- Constraints: Thick materials need careful hooping; jackets benefit from a sacrificial test piece; sublimation depends on correct time/temperature and secure wraps.
Quick check
- If any item is thick, plan a test stitch on a similar material first. This prevents costly errors on premium garments.
Prep: Designs, Materials, Machines, and Workspace Files and designs
- Embroidery: Logos for beanies, saddle pads, and jackets (digitized for each substrate).
- Sublimation: Ready-to-press prints for 4-in-1 can coolers.
- Screen prints: Transfers sized for left-chest placement on hoodies/tees.
Materials
- Beanies (with tear-away stabilizer), saddle pads, Bernie-brand jackets similar to Carhartt style, hats and leather patches.
- HOGG 4-in-1 can coolers; sublimation paper, sublimation tape, sublimation ink.
- Hoodies and t-shirts; screen print transfers.
Tools and machines
- Embroidery machines (Ricoma models are shown in action), scissors, seam ripper, tweezers, lighter.
- Hooping aids for thick items (clamps and fast frames).
- Heat press and T-square ruler for placement; tape dispenser.
- Mug/tumbler heat press; heat-resistant gloves.
Workspace
- Clear finishing table for trimming and boxing.
- Nearby staging for in/out trays and packaging.
From the comments
- Digitizing is outsourced to Dream Digitizing; if you don’t digitize in-house, plan lead time accordingly.
Prep checklist
- Designs match substrates and sizes.
- Stabilizers and consumables stocked for the full run.
- Heat press and mug press warmed up; gloves available.
- Packaging and labels ready.
Setup: Hooping Choices, Thread Weight, and Test-Stitch Strategy Small text on knits - For tiny beanie text, step down to 60-weight thread for finer detail and legibility. The sample beanie design was about 2 inches tall and finished cleanly.
Thick items (saddle pads and jackets)
- Use clamps and compatible fast frames for rigid or padded items; the goal is zero shifting under the needle.
- Before running an expensive jacket, stitch the logo on a similar thick sacrificial piece (a puffy jacket works well) and evaluate density, pull-compensation, and coverage.
Why test stitches matter
- Thick textiles can deflect needles, pucker, or distort columns. A test lets you confirm stabilizer strategy and stitch density without risking the job.
From the comments
- On thick garments, adding a clamp even on a magnetic frame adds security; jackets can pop off mid-stitch. This is why some shops double up—magnetic plus clamp—on bulky outerwear. ricoma mighty hoops
Setup checklist
- Thread weights selected for each item (60-weight for tiny beanie text).
- Clamps and frames staged; test material hooped for jackets.
- T-square on the press for left-chest alignment.
Operation: Step-by-Step Production 1) Finish embroidered beanies (batch of 50) - Trim: Cut away tear-away stabilizer from the back of each beanie so it’s comfortable to wear.
- Tidy thread: Use tweezers and a lighter to singe any fuzz or micro tails—be gentle and keep moving to avoid scorching.
- Fold and stack: Keep sizes/logos facing consistently for easy counting and boxing.
Expected result: Clean backs, no scratchy stabilizer edges, and crisp small text that reads clearly. magnetic hoop embroidery
Watch out
- Leaving stabilizer edges can irritate the wearer; trim right up to the stitching.
Quick check
- Run your thumb over the back—feel any hard stabilizer edges? Re-trim.
2) Embroider saddle pads - Hoop: Secure pads with clamps and an 8-in-1 style fast frame or equivalent. The goal is zero pad movement relative to the frame.
- Load design: Bring the digitized logo into the Ricoma and position accurately.
- Stitch with supervision: Thick items deserve eyes on the first minutes; pause if you hear deflection or see wobble.
- Unhoop and clean: Trim stabilizer edges and loose threads.
Expected result: Stable logo placement with consistent stitch formation across quilted zones. ricoma 8 in 1 device
Pro tip
- Quilted diamonds may vary between pads; center by eye for best visual outcome, not just by numeric position.
3) Embroider Carhartt-style jackets (Bernie brand in this run) - Test stitch: On a sacrificial puffy jacket, run the full-size back logo first. Evaluate density, any tunneling, and color registration.
- Hoop real jackets: Stabilize appropriately and ensure the garment can’t creep under the hoop.
- Run left chest and large back logos: Monitor the early passes, then spot-check periodically.
Expected result: Clean left chest plus a large, full-back logo with no puckering.
Watch out
- Needle deflection on thick, cushioned materials can cause outlines to drift. Slow slightly on dense fills.
From the comments
- On some outerwear, extra clamping over a magnetic frame helps prevent mid-run pop-offs—worth the insurance for big backs. fast frames embroidery
4) Sublimate 4-in-1 can coolers (HOGG brand) - Prep blanks: Unbox, remove protective films, and line up on a clean surface.
- Wrap designs: Align and tape tightly with sublimation tape; ensure no gaps.
- Press: In a mug heat press, run at 160°F for about 60 seconds; wear heat-resistant gloves.
- Reveal: Remove paper and inspect for full, even color.
Expected result: Vibrant transfers with full coverage, no ghosting, and seams aligned. magnetic hoops for embroidery
Watch out
- A customer reported leakage with these 4-in-1s; the maker’s stress test showed a few drops at the twist seam when shaken hard. If a client notes functional issues, treat it as legitimate feedback and evaluate your supplier.
Pro tip
- If a defect is reported, ask the customer for their ideal resolution. Many prefer a replacement or fix; refund becomes your last resort once other remedies are exhausted.
5) Apply screen print transfers (hoodies and tees) - Position: Use a T-square to center left-chest transfers consistently.
- Press: Follow the transfer’s spec; apply firm, even pressure.
- Cool and check: Peel per transfer instructions; inspect corners and fine strokes.
- Repeat and stack: Fold consistently for neat boxing.
Expected result: Straight, centered left-chest logos with complete adhesion and clean edges. mighty hoop left chest placement
Quick check
- Tug gently at a letter corner; if it lifts, re-press with a cover sheet for a short burst.
6) Hats with embroidery and leather patches
- Embroidered hats: Verify clean stitching on the crown; avoid seam pull.
- Leather patches: Iron-on patches adhere easily when heat and pressure are correct; confirm full edge bond.
Expected result: Six embroidered hats and twelve leather-patch hats, ready for delivery.
Operation checklist
- Beanies trimmed and thread-cleaned.
- Saddle pads hooped rigidly; stitches monitored at start.
- Jackets test-stitched; backs run clean.
- Tumblers taped tight; time/temperature verified.
- Transfers straight and bonded; hats finished and boxed. ricoma mighty hoops
Quality Checks: What “Good” Looks Like Embroidered beanies
- Back feels smooth against skin; no hard stabilizer corners.
- Tiny text edges read sharply (thanks to 60-weight thread).
Saddle pads
- No shifting evident in satin borders or fill alignment.
- Consistent logo placement relative to the pad’s quilting pattern.
Jackets
- No puckering around dense areas; outlines align at color boundaries.
- Back logo sits square across the panel; chest logo balanced.
Tumblers
- Uniform color with no light spots or ghost halos.
- Functional test: Assemble lids and check for drips; document any found.
Transfers on garments
- Straight, centered placement; no corner lift or silvering.
- Fabric surface undisturbed (no scorch or sheen from over-pressing).
Quick check
- Photograph one hero piece per item type for your records and to standardize future QC.
Results & Handoff: Packaging, Pickup, and Records - Batch boxing: Keep each client’s SKUs together—beanies first if pickup is scheduled sooner.
- Labeling: Include quantities, garment types, and care cards where applicable.
- Delivery: Confirm counts at handoff; obtain a simple receipt photo or signature.
- Records: Save mockups, stitch counts, and press settings; archive photos of finished goods for reference.
From the comments
- Growing order flow takes time; the creator shared a separate resource for getting started. Build trust through consistent quality and responsive service.
Troubleshooting & Recovery: Fast Fixes and Customer Care Embroidery issues
- Symptom: Puckering on thick jackets.
Likely cause: Excess density or insufficient stabilization. Fix: Adjust density in the file and add/upgrade stabilizer; re-test on a sacrificial jacket.
- Symptom: Frame pop-off mid-run on outerwear.
Likely cause: Bulk fighting the hoop magnets/clamps. Fix: Add an extra clamp for security on thick items.
Sublimation issues
- Symptom: Ghosted or pale transfers.
Likely cause: Insufficient pressure, time, or temperature; loose wrap. Fix: Re-wrap tightly; verify 160°F and ~60s; ensure full contact in the press.
- Symptom: Customer reports leaking tumblers.
Likely cause: Product hardware tolerance at twist seam. Fix: Validate with a water-shake test; if replicated, contact supplier with photos/video and lot details. Consider refund or replacement per policy. From the community: some shops request product returns before refunding, or try compatible lids with better seals first.
Screen transfer issues
- Symptom: Edge lift after cooling.
Likely cause: Under-pressing. Fix: Re-press with cover sheet; increase pressure slightly per transfer spec.
Customer service playbook
- Ask for the client’s ideal resolution first.
- If you refund, request returns so you can inspect and pursue supplier credit.
- Document defects and keep batch details.
Watch out
- One small bad experience can overshadow a great order. Transparent, proactive fixes preserve long-term relationships. mighty hoops for brother
From the comments: Real-world Q&A
- Are you using screen transfers for the sweater? Yes, screen print transfers were used on the sweaters/hoodies and tees.
- Who does your digitizing? The work here was outsourced to Dream Digitizing.
- Why add a clamp to a magnetic frame? Extra clamping helps prevent mid-stitch pop-offs on bulky jackets.
- How to handle leaky tumblers? Several shop owners recommended refunding the client, requesting a product return, then pursuing supplier credit. Another suggestion was to test alternate lids with better seals before refunding as a last resort. magnetic hoop for brother
Appendix: Settings and safety used here
- Thread: 60-weight for fine white text on beanies (about 2" tall logos).
- Sublimation: ~160°F for ~60 seconds in a mug press; tight tape wrap is essential.
- Safety: Use heat-resistant gloves when handling hot tumblers and presses.
- Precheck: Always test-stitch on a thick sacrificial garment before embroidering customer jackets.
Pro tip
- For bulky items like saddle pads and outerwear, rigid hooping and test stitches save hours. Many shops rely on clamps/fast-frames for control on thick substrates. magnetic hoops