If you’ve ever wondered how to level up your shop without blowing the budget or rebuilding your floor plan from scratch, episode 268 of the Shirt Show podcast is packed with the kind of real-life wins and lessons every screen printer should hear. Hosts Dylan and Zach share their stories - failures and all - on upgrades, mistakes, hiring, and making your space work smarter, not harder.
NO GLASS = NO PINHOLES
It’s always the little things. Zach shared how his shop’s pinhole problem basically disappeared after switching to an exposure unit without glass. Why? Nothing was diffusing or bouncing the light. That direct light exposure, paired with CTS output, made an immediate difference in screen quality. Something as simple as ditching the glass helped eliminate an entire headache.
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SCREEN QUALITY MATTERS MORE THAN YOU THINK
Another game-changer? Tension data. Zach started labeling screens by color and date and rotating out low-tension screens sooner. The result: fewer registration issues and faster setups. Combine that with a consistent coating process (like with an autocoater), and you’ve got a darkroom that runs like a machine.
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PROOFING LIKE A PRO
The guys also dig into one of the most avoidable sources of reprints: weak mockups. Zach’s solution was to build a Photoshop-based proof template with clear print sizes, Pantones, placements, and measurements. Clients get all the info before hitting “approve.” The reward? Reprint rates nearly disappeared. And any mistakes that do happen? They’re covered—because the approval was documented down to the inch.
THE SHOP HACKS THAT JUST MAKE SENSE
- Hat insert tags: Reuse those stiff backings from caps to tag youth sizes or color change sections. Write the note in Sharpie and drop it in the collar - it survives the dryer and helps catchers stay organized.
- Tape trick: QC team places a piece of tape on the sleeve being printed. No more mix-ups on left/right sleeve jobs.
- Humidity help: A fogger or steamer (even one meant for reptiles) next to the press helps keep water-based inks flowing in dry shops.
BOUNCE TECHNIQUE = MORE JOBS OUT THE DOOR
When you’re short on crew or presses, every minute counts. Dylan talked about using the “bounce method,” where one press operator is always printing while the next job is being set up on a second press. Once that job is ready, the printer “bounces” to the next machine: no downtime, no waiting for setup.
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CULTURE STILL WINS
Even with all the gear talk, some of the best takeaways were about leadership. Zach’s bonus philosophy is simple: give when you can, but don’t make it expected. And when it comes to hard conversations? If it’s not your strength, empower someone who can. Build your shop around what you’re good at, and create a place people want to work.
VISIT OTHER SHOPS, LEARN SOMETHING NEW
Zach’s biggest growth hack? Visit other print shops. He shares how every trip—whether to a major city or just down the road—teaches him something. It’s never the flashy upgrades. It’s usually something small, smart, and easy to steal: a rack built at the right height, a system for organizing tape removal, or a layout that just flows better.
FINAL TAKEAWAY: TRIAL > THEORY
There’s no single “right” way to run your shop. Zach said it best: “You can watch a consultant say one thing and another say the opposite. You just have to try stuff and find what works for you.”
And that’s the heart of it—every print shop is a little different. But when printers share what’s working, the whole community levels up. That’s what this episode was about.
Want more real shop talk? Catch the full Shirt Show episode above and dig deeper into the strategies that help your shop grow smarter, not harder. Watch More Shirt Show here.