Overruns in screen printing are standard practice, but they often catch customers off guard if they don't understand why they're charged for pieces they didn't order. Understanding screen printing overruns helps you budget accurately and negotiate fair terms with your printer.
What Are Screen Printing Overruns?
Overruns are extra printed pieces produced beyond your exact order quantity. When you order 500 shirts, your printer might deliver 510–525 pieces and charge you for the extras. This happens because screen printing involves setup costs, ink consistency, and production efficiency that make printing a few extra pieces cheaper than stopping the machine at an exact number.
Most professional screen printers build overruns into their pricing model. It's not a surprise fee—it's a standard part of the process that you should see outlined in your quote.
Why Do Overruns Happen?
Screen printing machines don't stop on a dime. Once the press is running and color registration (ink alignment) is dialed in, continuing to the next shirt takes seconds. Stopping mid-production creates downtime and wastes setup effort. Additionally, printers account for:
- Setup waste: The first 5–15 pieces might have slight imperfections as the printer adjusts ink density and color match
- Quality control: A few pieces are inspected and sometimes removed from your order
- Ink and screen limitations: Running a few extra pieces uses minimal additional ink once the screen is prepared
Industry Standards for Overruns
Most screen printers charge overruns at 5–10% above your order quantity. Some charge the full unit price; others offer a modest discount on overrun pieces. Here's what to expect:
- Standard overrun allowance: 5–10% of your order quantity (order 200, receive 210–220)
- Premium or specialty ink colors: May allow up to 15% overruns
- Small orders under 50 pieces: Sometimes capped at 5% overruns to avoid excessive extras
- Large orders over 500 pieces: Often fall to the lower end of the overrun range due to production efficiency
Always ask your printer upfront: "What's your overrun policy?" A reputable printer will state this clearly in writing before you approve the quote.
How Overruns Affect Your Budget
If you're ordering 300 shirts at $8 per piece, you're budgeting $2,400. A 10% overrun means you'll receive 330 shirts and pay approximately $2,640—an extra $240. Over a large order, that adds up fast.
Ways to manage overrun costs:
- Negotiate a flat overrun cap (e.g., "no more than 5% charged") in your contract
- Request that overrun pieces be discounted 10–15% below the per-unit price
- Order slightly under your target quantity if you're budget-constrained, knowing overruns will get you closer to your real need
- Ask if the printer will donate or keep overrun pieces instead of charging you (rare, but worth asking for high-volume orders)
What to Look for in an Overrun Policy
When comparing screen printing providers—whether you're using platforms like Mercoly that help you find and compare trusted custom apparel vendors, or contacting printers directly—check their overrun terms:
- Is the overrun policy in writing? Verbal agreements lead to disputes. Get it in your quote or contract.
- Are overrun pieces the same quality as your order? You shouldn't receive seconds or rejected pieces as overruns.
- Can you refuse overruns? Some printers allow you to decline extras; others charge regardless. Clarify this upfront.
- Do you get a discount on overruns? If overruns are charged at the full unit price, negotiate a 10–15% reduction.
Red Flags to Avoid
Steer clear of printers who don't disclose overrun policies upfront or who charge surprise overrun fees significantly above 10%. If a quote doesn't mention overruns at all, ask before signing. Trustworthy printers are transparent about this cost from the start.
Frequently Asked Questions
Q: Can I specify "no overruns" and get charged only for my exact order quantity? Most printers can't guarantee zero overruns due to production mechanics, but some small-run or digital-hybrid printers offer this option for a premium price or minimum order increase.
Q: What happens if I receive overruns I don't want? Check your contract first—some printers allow returns within 30 days, while others charge regardless. Always confirm the return or refund policy before ordering.
Q: Are overrun pieces usually defective? No, overrun pieces should meet the same quality standard as your main order. If they're noticeably different in color or fit, ask your printer to replace them.
Ready to order? Compare screen printing providers with transparent overrun policies and get quotes that break down costs clearly.