To celebrate the 300th episode of Shirt Show, Dylan sits down with Dave Swart of New Buffalo. Dave shares his transition from an IT professional to a leader in one of the most recognized names in the screen printing industry. The conversation covers the evolution of New Buffalo from a large scale sports and music powerhouse to its modern iteration.
Dave provides a behind the scenes look at the legendary New Buffalo culture, the complexities of printing for global brands like Disney and Nike, and the reality of being acquired by a corporate giant. From the innovative M&R print truck to the challenges of nearshore manufacturing in Honduras, this episode is a deep dive into the history and future of high level garment decoration.
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THE LEGENDARY CULTURE OF NEW BUFFALO
Dave reflects on the original New Buffalo Shirt Factory as a melting pot of talent and personality. He describes an environment where innovation was constant and the workforce was driven by the charisma of founder John Weiss. The shop was known for tackling the most difficult jobs in the industry, often running 12 to 14 colors as a standard rather than an exception.
This culture of high performance and creativity drew in world class printers and artists. Dave notes that while the industry has shifted toward more formal processes, the original spirit of New Buffalo was defined by the people and their collective passion for the craft. Bringing many of those original team members back for New Buffalo 2.0 has been a primary point of pride in his career.
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FROM DOMESTIC SCALE TO OFFSHORE OPERATIONS
The journey included massive expansion, notably opening a 100,000 square foot facility in Honduras to serve major clients like Disney and Nike. Dave explains the logistical and financial hurdles of building a factory overseas, where traditional support systems are often unavailable. This move was driven by the need to nearshore production while remaining competitive for high volume retail accounts.
Working with global brands required a shift toward non PVC inks and extremely tight tolerances, especially when printing on 100% polyester performance wear. These experiences prepared the team for the eventual acquisition by Gildan, which shifted Dave into a corporate role before he eventually decided to return to his roots in Buffalo to restart the business on his own terms.
RESTARTING WITH INTENTION IN 2026
New Buffalo 2.0 began with a goal of being a smaller, boutique operation focused on high end execution. Dave discusses the reality of scaling back up as demand returned, leading to the current 36,000 square foot facility. He emphasizes the importance of hiring a CFO to handle the backend, allowing him to focus on his true passion: the production floor and technical innovation.
Looking toward 2026, Dave highlights a shift in mindset influenced by the "Ted Lasso" philosophy—prioritizing positivity, team well being, and authentic leadership. He shares his goals of building a sustainable legacy that benefits his employees while allowing himself the space to explore life beyond the press.
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KEY TAKEAWAYS
- Innovation requires grit. Scaling to an international level involves significant risks that demand persistence and technical expertise.
- People are the priority. A successful shop is built on the talent and dedication of its team members, not just the equipment.
- Know when to pivot. Moving from a corporate structure back to an independent shop requires a clear vision of your personal and business goals.
- Variables are constant. No matter the level of process, screen printing will always present environmental and technical challenges that require hands on troubleshooting.
- Focus on your strengths. Delegating financial management to a CFO allows a production minded owner to drive innovation and quality.