In episode 321 of Shirt Show, host Dylan Gilligan sits down with Dennis Condusta, production manager at Axelrad Screen Printing. Dennis shares how Axelrad evolved from a DIY garage setup into a high-capacity commercial print facility running multiple automatic presses.
The conversation covers the practical steps of scaling a print shop, managing production metrics, cross-training staff, and balancing efficiency with high-quality artistic standards. Dennis explains how maintaining clear systems allows a shop to grow while preserving the human element of screen printing.
FROM DIY PUNK ROOTS TO SCALED PRODUCTION
Dennis entered screen printing through the DIY punk and BMX scenes, purchasing a manual press at age 17 before partnering with shop owner Dave. Axelrad began operating out of a basement in 2005 before transitioning into commercial locations in 2009. As the shop expanded, managing daily operations required establishing structured procedures for ink inventory, receiving, and workflow organization.
To maintain consistent output without burning out staff, Axelrad introduced flexible scheduling, including four-day, ten-hour workweeks for printers and cross-training across all production roles. Cross-training enables team members to shift between ink mixing, screen reclaiming, and printing based on daily volume shifts.
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TRANSITIONING FROM CONTRACT PRINTING TO DIRECT CLIENT RELATIONSHIPS
For its first six to eight years, Axelrad functioned primarily as a contract print shop, executing high-volume fulfillment for paper printers, uniform companies, and trade accounts. While contract work helped build shop infrastructure and press speed, it limited direct customer communication and overall profitability.
Axelrad gradually shifted its business model toward direct sales and in-house client management. Building a dedicated internal sales team allowed the shop to partner directly with touring bands, local businesses, and regional accounts. This transition gave the shop control over production schedules, garment choices, and long-term client relationships.
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BALANCING PRODUCTION METRICS WITH REAL-WORLD PROBLEM SOLVING
Data plays a central role in managing shop efficiency, but metrics must reflect realistic floor conditions. Dennis spent nine months tracking output across six automatic presses to establish accurate baseline time averages for setup and production runs. These metrics inform job scheduling, labor costing, and sales expectations.
However, screen printing involves physical variables that metrics alone cannot resolve. Temperature changes, ink viscosity shifts, and mechanical issues require active problem-solving from experienced operators. Rather than using data for strict enforcement, Axelrad uses metrics to identify bottlenecks, refine staging workflows, and support operator output.
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SERVICING HIGH-END ARTISTS AND EXPANDING SHOP CAPABILITIES
Printing for quality-focused artists, such as musical act Billy Strings, requires strict quality control systems. Executing tour merchandise with 8 to 10 colors, inside neck prints, discharge bases, and custom hand-applied finishes demands exact Pantone mixing and multi-point inspection checks. High-detail production elevates standards across all shop lines.
To serve diverse account needs, Axelrad continually evaluates complementary decoration technologies alongside traditional screen printing. Incorporating Direct-to-Film transfer equipment for short-run requests, alongside sublimation and laser darkroom imaging, allows the facility to provide comprehensive fulfillment while maintaining core screen printing efficiency.
KEY TAKEAWAYS
- Cross-training builds flexible capacity. Training employees across multiple production departments allows a shop to adapt to daily volume shifts without overstaffing.
- Base metrics on multi-month averages. Gathering press data over several months establishes realistic production baselines for scheduling and pricing.
- Direct relationships improve job control. Moving away from contract printing allows print shops to manage garment quality and build repeatable client accounts.
- Strict checkpoints prevent production errors. Implementing standardized Pantone checks and staging protocols protects complex multi-color print runs.
- Digital decoration complements traditional screen printing. Utilizing tools like DTF for low-quantity orders keeps screen presses open for high-volume jobs.