This week on Shirt Show, Dylan catches up with TeeJay Henry, the print engineer at Pine Printshop in Fort Collins, Colorado. TeeJay shares his unique perspective as a dedicated industry professional who lives and breathes screen printing. His passion for the craft is so strong that after working 10-hour days at a high-volume commercial shop, he goes home to build and run his own manual screen printing setup in his garage.
TeeJay details his journey from a background in graphic design to learning the mechanics of apparel decoration. The conversation covers his quick progression through the ranks at Pine Printshop, balancing production demands, and the valuable lessons learned from navigating structural roles within a rapidly growing team. It is an insightful look at what it means to possess an owner mindset as a key team member.
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THE TRANSITION FROM MANAGEMENT BACK TO PRESS
When Pine Printshop experienced a sudden shift in production staff, TeeJay stepped into a management role to oversee scheduling and operations. While the promotion reflected the company's trust in his abilities, TeeJay quickly realized that sitting behind a desk and managing administrative tasks did not align with his professional strengths or personal fulfillment.
He shares the humbling experience of recognizing his true lane and having an open, transparent conversation with shop owner Garrett. By stepping back to the press floor as a print engineer, TeeJay returned to what fills his cup: hands-on problem solving, micro-registration, and mastering complex multi-color setups. This move allowed him to continue driving quality where it impacts the shop most.
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THE UNIQUE VARIABLES OF WATER-BASED PRINTING
Pine Printshop specializes heavily in water-based and discharge ink systems, which present specific production challenges compared to traditional plastisol. TeeJay explains how environmental factors in Colorado require a strict workflow to prevent ink from drying in the screens during a run. The team enforces a rule where screens must be cleaned down immediately if production pauses for more than two minutes.
Despite the steep learning curve and constant adjustments for variables like pallet temperature and ink viscosity, TeeJay advocates for the benefits of water-based printing. The premium hand feel and breathability provide a significant advantage, especially for high-detail designs and large bulk orders that demand retail-ready quality.
THE LOGISTICS OF HIGH-VOLUME BANDANA PRODUCTION
A substantial portion of Pine Printshop's core volume consists of custom bandana production, a niche that brings its own set of technical hurdles. Bandanas are notoriously thin and rarely perfectly square, making registration and ink coverage difficult on large runs. TeeJay discusses how switching to custom-sized print grip pallets that match the exact dimensions of the bandanas resolved severe material lifting and screen damage issues.
Managing large bandana orders requires absolute consistency across both automatic presses. TeeJay highlights why trade outsourcing makes operational sense for standard manual print shops that are not explicitly equipped with the specialized pallet setups and water-based experience required to handle these challenging substrates profitably.
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REAL-WORLD LESSONS FROM A HOME SHOP STARTUP
Setting up a manual shop at home gave TeeJay a quick reality check regarding the complexities of running a business. He recounts his experience with his first independent garage client, a local brewery, which ultimately fell through after extensive preparation, custom color mixing, and sample proofing. The setback highlighted a critical industry rule: always secure an upfront deposit or signed invoice before commencing any stage of production.
Operating a home press while maintaining a full-time position at a commercial shop provides TeeJay with a well-rounded understanding of print mechanics. The troubleshooting skills built on his manual home press directly translate to greater efficiency and sharper instincts when managing automation and registration on the commercial floor.
KEY TAKEAWAYS
- Identify your true lane. Leadership titles mean nothing if the daily tasks remove you from your actual strengths and passion.
- Water-based printing requires discipline. High-solid acrylic and discharge inks demand constant movement and quick screen management to prevent mid-run drying.
- Protect your time and capital. Always establish clear pricing, clear proofs, and secure upfront deposits to validate an order before burning screens.
- Specialized jobs require specialized tools. High-volume substrates like bandanas require specific modifications like custom print grip templates to avoid workflow bottlenecks.
- The value of an analog foundation. Learning the subtle tactile feedback of a manual press refines a printer's ability to dial in automation variables like off-contact and squeegee pressure.