Many apparel print-on-demand businesses define themselves in a very one-dimensional way. They describe themselves as “I’m a screen printing shop,” “I do DTF,” “I’m in dye sub,” or “I do DTG.” But when it comes to apparel, there is no single perfect manufacturing solution. Your minimum order quantity capability, the fabric types you support, and the feel of the fabric all determine the best technology to use for a given order.
One of the key benefits of automation is that, rather than defining your business purely by a specific technical capability—DTF, DTG, or otherwise—automation enables multiple production methods to operate seamlessly within your business. Efficiency is built into the process itself, making multi-technology production highly effective.
A good example of this is DTF versus DTG. From a workflow perspective, these two processes are completely different.
- DTF follows a print-first workflow. An optimal batch is formed based on the best combination of goods that need to be produced within SLA requirements, ensuring the right quantity and garment type are grouped together. These are all printed to film first. Then, the batch members are picked and moved into the order association and pressing stage.
- DTG, on the other hand, is the inverse. It follows a pick-first workflow. All garments are picked first, with artwork automatically sequenced and batched to create an optimized print queue. A simple barcode scan then releases the print job in real time directly onto the garment.
Automation can 100% manage both of these workflows seamlessly. It can also optimize picking efficiency, ensuring that whether you follow a pick-first or pick-second workflow, the process remains smooth and integrated within the team. From the pickers’ perspective, it doesn’t matter whether an order is being processed as DTF or DTG—the automation system ensures that the process remains seamless.
This same principle extends across the factory. Based on business rules—such as MOQ or fabric type—automation can automatically route orders into the appropriate DTG or DTF workflow. Alternatively, it can route orders into a manual switching function where an operator determines the best workflow. From that point forward, automation handles everything—queuing, batching, picking, and all post-print and pressing steps—ensuring a smooth, efficient process from order receipt to shipment.
When defining your business strategy, our advice from a ZenSmart perspective is to focus on the customer and market segment you serve. Use that to determine the right production technologies to maximize your competitive advantage. Then, rely on automation to simplify factory operations, creating a streamlined, scalable process. This approach not only delivers a significant competitive edge but also unlocks new growth opportunities for your business.
