Bulk Ordering Guide: How to Save on Large Custom Apparel Orders
Master the art of bulk ordering and save on your custom apparel. Expert strategies for volume discounts, budget-friendly blanks, print optimization, and getting the best pricing in Canada.
Why Bulk Ordering Makes Financial Sense
Whether you're outfitting a corporate team, organizing a community event, or launching a merchandise line, ordering custom apparel in bulk is the smartest way to maximize your budget. At T-Shirt Elephant, we've helped thousands of Canadian businesses and organizations save significantly on their custom apparel orders through strategic bulk purchasing.
The math is simple: the more you order, the less you pay per piece. But the real savings come from understanding how to optimize your order—from choosing the right blank garments to minimizing print costs and negotiating the best possible pricing with your supplier.
This comprehensive guide will walk you through every strategy for reducing costs without sacrificing quality. You'll learn which budget blanks offer the best value, how to structure your artwork for maximum savings, and when to contact our customer service team for custom bulk pricing that beats our standard rates.
T-Shirt Elephant Tip
For orders over 100 pieces, always contact our team directly. We regularly offer custom pricing that isn't available through our online calculator, plus dedicated support to ensure your large order goes smoothly. Reach out here or use our live chat.
Understanding Volume Discount Tiers
Bulk pricing in custom apparel follows a tiered structure where per-unit costs decrease as quantities increase. Prices drop at 12, 20, 25, 50, 75, 100, 125, 150, 200, 250, 500 and 1,000 pieces. Here's what that saves per shirt against a 12-piece order, for a one-colour front print on a Gildan 5000 with setup included:
Savings Example
Let's look at how these discounts translate to actual savings on a common order scenario—custom t-shirts with a one-color front print on a Gildan 5000, setup included (a single shirt is printed full-colour DTF):
| Quantity | Per-Unit Cost | Total Cost | Savings vs. Single |
|---|---|---|---|
| 1 shirt | $24.95 | $24.95 | — |
| 24 shirts | $16.99 | $407.76 | 32% per unit |
| 48 shirts | $15.47 | $742.56 | 38% per unit |
| 100 shirts | $11.70 | $1,170.00 | 53% per unit |
| 250 shirts | $10.05 | $2,512.50 | 60% per unit |
| 500 shirts | $9.00 | $4,500.00 | 64% per unit |
As you can see, ordering 100 shirts instead of buying them individually saves you 53% per shirt. That's $13.25 in savings multiplied by 100—a total of $1,325.00 back in your pocket.
Choosing Budget-Friendly Blank Garments
The blank garment you choose has a massive impact on your total order cost. While premium blanks offer superior feel and fit, budget-friendly options can deliver excellent value—especially for large orders where every dollar per unit matters.
Here are our top recommendations for bulk orders, ranging from budget to premium quality, all at competitive price points:
Gildan 5000 Heavy Cotton
- 5.3 oz heavyweight cotton
- 60+ colors available
- Sizes S-5XL
- Excellent print surface
- Industry standard for bulk orders
The go-to choice for promotional events, giveaways, and budget-conscious bulk orders. Durable construction holds up to frequent washing.
Read Full Review (4.1/5)Gildan 64000 Softstyle
- 4.5 oz ring-spun cotton
- Softer, more fitted feel
- Modern retail-ready look
- Same price as budget options
- Great for resale merchandise
Ring-spun cotton at budget prices. The sweet spot between quality and value—perfect when you want shirts people will actually wear.
Read Full Review (4.1/5)Parkour S05610
- Ring-spun combed cotton
- Retail-quality softness
- Pre-shrunk fabric
- Tear-away labels
- Exceptional at this price point
Premium quality at a budget price. The combed cotton process removes short fibers for an incredibly smooth finish. Our hidden gem for quality-conscious buyers.
Read Full Review (4.2/5)Quality vs. Price: Our Recommendation
For most bulk orders, we recommend the Gildan 64000 Softstyle or Parkour S05610. You get ring-spun cotton quality at $5.75 (Gildan 64000) or $5.75 (Parkour S05610) a blank, against $4.95 for the basic Gildan 5000. This small investment in quality means recipients actually wear and appreciate the shirts—maximizing the value of your promotional spend.
When to Choose Budget vs. Premium Blanks
| Use Case | Recommended Blank | Why |
|---|---|---|
| Event giveaways | Gildan 5000 | Maximum budget efficiency, wide size range |
| Employee uniforms | Gildan 64000 or Parkour | Comfort for all-day wear, professional look |
| Merchandise for resale | Parkour S05610 | Premium feel justifies retail pricing |
| Sports teams | Performance fabrics | Moisture-wicking for athletic use |
| Fundraisers | Gildan 5000 or 64000 | Balance of cost and quality for donations |
Reducing Print Costs: Smart Design Strategies
Beyond the blank garment, your decoration choices have the biggest impact on per-unit costs. Here are proven strategies to minimize printing expenses without compromising your design vision.
Single Print Location Save 37%
Printing on the front only instead of front and back cuts your print costs nearly in half. Each additional location requires separate setup and production time. On 100 Gildan 5000s with one colour per location, a front print is $11.70 a shirt against $18.45 front and back.
Fewer Colours Save 11%
For screen printing, each color requires a separate screen and pass. On 100 Gildan 5000s, a one-colour front is $11.70 a shirt against $13.20 in four colours. Consider single-color designs with creative use of negative space.
Consolidated Shipping Save on Freight
Order everything at once rather than multiple smaller orders. Bulk shipping rates are significantly lower per unit than multiple shipments.
Screen Printing vs. DTF: Cost Comparison for Bulk Orders
Your choice of print method significantly impacts bulk order pricing. Here's how they compare:
Screen Printing
- Setup: $25.00 per colour per location
- Per-unit cost: Lowest at 100+ pcs
- Color limit: 1-6 colors typical
- Break-even: ~50 pieces
Learn about our screen printing services →
DTF Printing
- Setup: None (no screens needed)
- Per-unit cost: Fixed regardless of colors
- Color limit: Unlimited
- Break-even: Under 50 pieces
For a detailed comparison of these methods, see our comprehensive Screen Printing vs DTF Guide.
Watch for Hidden Costs
- Size upcharges: Sizes 2XL and up add $3.00 per piece.
- Pantone matching: Custom color matching costs extra per color
- Rush fees: Guaranteed rush dates add 30% to 100% of the product subtotal
- Art setup: Complex artwork may require additional prep fees
Contact Customer Service for Best Pricing
Here's an insider tip that can save you hundreds or even thousands of dollars: always contact customer service for large orders. Online calculators show standard pricing, but our team has flexibility to offer custom quotes that reflect your specific order needs.
When to Request a Custom Quote
- Orders over 100 pieces: Volume discounts beyond standard tiers
- Tight budgets: We can suggest alternatives that fit your budget
- Complex projects: Custom quotes for unique requirements
What to Include in Your Quote Request
Prepare This Information for the Best Quote
Ready to Get Your Custom Quote?
Our team responds to quote requests within 24 hours on business days. The more details you provide, the faster and more accurate your quote will be.
How to Reach T-Shirt Elephant
- Email: [email protected]
- Live Chat: Available on our website during business hours
- Quote Form: Submit detailed quote request
Balancing Quality and Budget
The cheapest option isn't always the best value. When planning bulk orders, consider the total value of your investment—including how the apparel reflects on your brand and whether recipients will actually wear it.
The True Cost of "Cheap" Shirts
A shirt that costs a little less per unit but gets thrown in a drawer after one wear is actually more expensive than a quality shirt that becomes a wardrobe staple. Consider:
- Brand impression: Cheap, scratchy shirts reflect poorly on your organization
- Wear frequency: Quality shirts get worn more, multiplying your brand exposure
- Recipient satisfaction: People remember who gave them a quality gift
- Longevity: Better construction means your branding stays visible longer
The Quality Multiplier
A $5.50 quality shirt worn 50 times costs $0.11 per impression. A $4.00 budget shirt worn 5 times costs $0.80 per impression. The "expensive" option is actually 7x more cost-effective for brand exposure.
Smart Spending: Where to Invest
| Order Type | Quality Level | Reasoning |
|---|---|---|
| Trade show giveaways | Budget (Gildan 5000) | High volume, broad distribution, promotional focus |
| Employee uniforms | Quality (Gildan 64000) | Daily wear, comfort matters, represents company |
| Customer appreciation gifts | Premium (Parkour S05610) | Relationship building, perceived value matters |
| Merchandise for sale | Premium | Customers paying expect quality, affects reviews |
| Team/club shirts | Quality to Premium | Pride in wearing, photo opportunities |
| One-time event shirts | Budget to Quality | Depends on event prestige and audience |
Planning Your Bulk Order: Step by Step
Successful bulk orders require careful planning. Follow this timeline to ensure smooth execution and maximize your savings.
Bulk Order Planning Timeline
Common Bulk Order Mistakes to Avoid
- Underestimating sizes: When in doubt, order larger. People prefer slightly loose over too tight.
- Forgetting size distribution: Don't order equal amounts of each size. Medium and Large typically represent 50-60% of orders.
- Waiting too long: Guaranteed rush dates add 30% to 100% of the product subtotal. Plan ahead!
- Not getting samples: A small sample investment can prevent a costly mistake.
- Ignoring shipping logistics: Factor in delivery time and coordinate receiving for large shipments.
Bulk Order Scenarios: Examples
Here's how different organizations optimize their bulk apparel orders:
Scenario 1: Corporate Event (500 Attendees)
Order: 550 custom t-shirts (includes 10% buffer)
- Blank: Gildan 5000 Heavy Cotton @ $4.95/unit
- Print: 1-color front screen print
- Result: $9.00/unit all-in, total $4,950.00
- Savings: 64% vs. single-shirt pricing
Scenario 2: Employee Uniforms (75 Staff)
Order: 150 polo shirts (2 per employee)
- Blank: Gildan 8800 polo @ $12.95/unit
- Print: Left chest embroidery (one thread colour)
- Result: $20.31/unit all-in, total $3,046.50
- Strategy: Quality investment for daily wear
Scenario 3: Fundraiser (200 Supporters)
Order: 220 custom t-shirts
- Blank: Gildan 64000 Softstyle @ $5.75/unit
- Print: 2-color front screen print
- Result: $11.73/unit all-in, total $2,580.60
- Strategy: Sell all 220 at $25/shirt for $2,919.40 profit
Scenario 4: Sports League (12 Teams)
Order: 180 jerseys with names/numbers
- Blank: Team 365 TT11 performance tee @ $8.95/unit
- Print: DTF front logo + name/number back
- Result: $34.95/unit all-in (names $8.00 and numbers $10.00 each), total $6,291.00
- Strategy: DTF handles individual customization efficiently
Why Order Bulk from T-Shirt Elephant?
As a Canadian custom apparel company with over 100,000 happy customers, we understand the unique needs of bulk buyers. Here's what sets us apart:
- No minimum orders: Whether you need 12 or 12,000, we've got you covered
- Both screen printing and DTF: We recommend the best method for your specific order
- Custom bulk pricing: Contact us for quotes that beat online calculators
- Canadian company: No surprise duties, faster shipping, local support
- Free design help: Our design team can optimize your artwork
- Quality guarantee: We stand behind every order we produce
Explore our full range of customizable products: T-Shirts, Hoodies & Sweatshirts, Polos, Performance Wear, and more.
Frequently Asked Questions
Bulk orders cost less per shirt: against 12 pieces, a one-colour print on a Gildan 5000 is ~39% off at 100 and ~58% off at 1,000. For example, a single custom Gildan 5000 is $24.95 with a full-colour DTF print, while ordering 100 of the same shirt brings a one-colour screen print down to $11.70 each, printing included. The savings increase with larger quantities, with orders of 500+ seeing the steepest discounts.
Bulk pricing starts at 12 pieces for screen printing. However, DTF printing has no minimums, making it ideal for smaller orders. Prices drop at 12, 20, 25, 50, 75, 100, 125, 150, 200, 250, 500 and 1,000 pieces. Contact T-Shirt Elephant for custom quotes on large orders.
The Gildan 5000 Heavy Cotton is the most popular budget option at $4.95 CAD with 60+ colors available. For a slight upgrade, the Gildan 64000 Softstyle offers ring-spun cotton at $5.75. The Parkour S05610 provides premium ring-spun combed cotton quality at budget-friendly pricing.
Reduce printing costs by limiting to one print location (front only), using fewer colors (1-2 for screen printing), choosing standard ink colors over Pantone matching, keeping designs under 12 inches, and consolidating orders into single shipments. On 100 Gildan 5000s, a one-colour front-only print costs 38% less per shirt than a two-colour front with a one-colour back.
Yes, always contact customer service for orders over 100 pieces. Custom quotes often include additional volume discounts not shown in online pricing and flexible payment terms for large orders. Email T-Shirt Elephant at [email protected].
The best strategy is finding quality at a low price point. Budget blanks like the Gildan 5000 work well for promotional giveaways, while ring-spun options like the Gildan 64000 or Parkour S05610 offer better quality at similar prices. For employee uniforms or resale, investing in quality blanks ensures customer satisfaction and repeat business.
Screen printing becomes more cost-effective at 50-100+ pieces for simple 1-3 color designs, with a one-colour print adding $4.05 per unit at 500 and $3.03 at 1,000. DTF printing is better for smaller quantities, multi-color designs, or orders requiring mixed sizes and colors. Screen printing setup fees are offset by lower per-piece costs at scale.
For bulk orders of 100+ pieces, plan 2-3 weeks ahead for standard production. Orders of 500+ may require 3-4 weeks. Rush services are available for additional fees. Early ordering also allows time for sample approval, design revisions, and ensures stock availability in all sizes and colors.
Yes, requesting samples before large orders is highly recommended. T-Shirt Elephant has no minimum order, so you can order 1-5 pieces first to verify print quality, colour accuracy, fit, and fabric feel. This small upfront investment can prevent costly mistakes on orders of hundreds or thousands of pieces.
Watch for setup fees per color and location, Pantone color matching fees, XXL and larger size upcharges, multiple location printing costs, rush order fees, and shipping costs for heavy bulk orders. Request an all-inclusive quote and ask about any potential additional charges before ordering. Sizes 2XL and up add $3.00 per piece.
Ready to Save on Your Bulk Order?
Let our team help you maximize your budget. Whether you need 50 shirts or 5,000, we'll find the perfect combination of quality and value for your project.
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