3 Ways to Lower Costs with Gang Sheets

In the world of custom apparel and promotional products, keeping costs low while delivering high-quality prints is essential for staying competitive. Whether you’re a distributor, decorator, team dealer, or e-commerce power seller, direct-to-film (DTF) gang sheets can be a game-changer for reducing your cost per design. By fitting multiple designs on a single sheet, you can maximize material usage and minimize your expenses. In this post, we’ll explore three effective ways to lower your costs using gang sheets.

Maximize Sheet Space

One of the biggest advantages of gang sheets is the ability to use every inch of the sheet to its full potential. When you maximize the sheet space, you get more value out of each order, ultimately lowering your cost per design. Here’s how you can do it:

Use Design Software for Precise Layouts

To ensure you’re using every bit of space efficiently, invest time in learning how to use design software effectively. Tools like Adobe Illustrator or CorelDRAW can help you arrange your artwork so that there’s minimal wasted space. The more designs you can fit on a single sheet, the lower your cost per piece. If you’re ordering transfers for smaller items like neck labels, sleeve prints, or left chest logos, you’ll be able to fit several pieces onto one sheet, reducing the cost per item dramatically.

Not a software wizard? No problem. Create a custom layout in seconds with our drag-and-drop Gang Sheet Builder!

Design for Different Sizes

Maximizing sheet space often means working with various design sizes. Don’t limit yourself to large logos or prints that take up a significant portion of the sheet. By incorporating smaller elements like neck labels, sleeve prints, or even hat placements, you can make sure every inch of the sheet is used. The more flexible you are with the sizes of your prints, the more opportunities you’ll have to fit extra designs on the same sheet.

Smaller designs tend to be overlooked when it comes to efficiency, but they’re perfect for filling those last bits of space on a gang sheet. For instance, if you’re ordering a large center chest design, you may have leftover areas on the sheet that can accommodate small logos or labels. If you don’t use these areas, you’re wasting material that could have been used to create additional products.

Test Layouts Before Ordering

Before finalizing your gang sheet order, test different layouts to see which configuration maximizes your sheet space. Even slight adjustments in spacing or orientation can allow you to fit more designs on a sheet. By experimenting with different layouts, you can squeeze more value out of each gang sheet, lowering the cost per design.

Consolidate Small Orders

If you frequently need small batches of transfers, gang sheets are a great way to save money by consolidating multiple designs into a single sheet. Here’s how this can work for you:

Combine Designs for Multiple Needs

If you have various designs that you need in small quantities, gang sheets allow you to combine them into one order. For example, you might need several logos for different projects or events, or you might be preparing for multiple promotions. Instead of ordering separate sheets for each design, you can arrange all the designs together on a single gang sheet, dramatically lowering your cost per design.

For example, if you need a few small left chest logos for a special event and some neck labels for your brand, you can fit them onto one gang sheet and save money by ordering them together. The cost savings are clear: one order, one sheet, but multiple finished products.

This method is particularly useful if you’re managing multiple projects or seasonal needs, as it allows you to plan ahead and reduce the number of orders you place.

Prepare for Reorders Efficiently

Gang sheets also make reorders more efficient. If you frequently need additional transfers for ongoing projects or clients, you can store your designs and quickly add them to future gang sheet orders as needed. This helps reduce the time and effort spent setting up each new order, as well as material costs for smaller batches.

For example, if a school regularly orders neck labels or small logos for uniform replacements, you can add their design to your next gang sheet order, instead of placing a separate order just for that one need.

Standardize Sizes

Standardizing your design sizes can simplify your ordering process and save money. While custom-sized prints can be necessary in some cases, sticking to a few standard dimensions makes it easier to optimize your gang sheets and keep costs low.

Create a Set of Standard Sizes

By developing a set of standard sizes for common designs—such as left chest logos, sleeve prints, and neck labels—you can reduce the amount of time spent arranging each gang sheet. This is particularly useful for businesses like e-commerce sellers and team dealers who often repeat similar designs across different products. When all your prints fit neatly into predetermined slots, you’ll find it easier to use space efficiently on each sheet.

For instance, you might create three standard sizes: a large design for the center chest, a smaller size for sleeve prints, and an even smaller size for neck labels. By sticking to these sizes, you’ll have more flexibility in arranging your designs on a gang sheet, knowing exactly how much space each one will take up.

Offer Standard Sizes to Your Customers

If you’re selling customized products, offering a set of standard sizes can also help your clients save money. This not only simplifies your workflow but also helps reduce costs for your clients, as standard-sized prints are easier to produce and arrange on gang sheets. If clients opt for these standard sizes, you can ensure that their designs fit seamlessly into your existing templates, saving time and material costs.

For example, a team dealer working with multiple sports teams might encourage all their clients to choose from a few standard sizes for jersey logos and names. By standardizing these options, you can streamline the ordering process and offer more competitive pricing.

Reduce Wasted Space

Standard sizes also help reduce wasted space on each gang sheet. When you’re working with consistent dimensions, it’s easier to arrange multiple designs in a way that leaves little to no unused space. The more you can fill each gang sheet, the lower your overall material costs will be.

Leverage Gang Sheets for Cost Efficiency

Using gang sheets is one of the most effective ways to lower your cost per design while maintaining high-quality output. By maximizing sheet space, consolidating small orders, and standardizing print sizes, you can reduce material waste, lower setup costs, and optimize your ordering process. Whether you’re working with team dealers, promotional companies, decorators, or e-commerce power sellers, these strategies will help you get the most out of your gang sheets and boost your bottom line.

Gang sheets are particularly useful for DTF transfers, where there are no minimums or fees, making them perfect for small placements and custom orders. By applying these three strategies, you can offer competitive pricing to your customers while maintaining healthy profit margins.

Start optimizing your gang sheets today and see the difference it makes in your business’s cost efficiency! No artist? No problem. Drag-and-drop your designs in our Gang Sheet Builder to create a custom layout in seconds!