All of our teamwear is stored in the warehouse as blank garments with no specific logos on them. Orders are received and processed in batches so that a picking list can be produced.
All garments are then taken from stock and placed in tub ready for sorting.
Once all the garments have been selected, the next process is to sort them into their separate crates. To aid production and speed up the process, each order is given its own crate. A job sheet is printed which tells the production team exactly which logos and personalisation goes on each garment.
This is a process where logos are printed with special ink and paper, the paper is then laid over the garment and heated to 200 degrees. This causes the ink to sublimate directly into the garment. Although only suitable for whites, it does allow us to get a much higher level of accuracy in replicating the club logo, making more colours available.
Garments with a dark colour must be embroidered. Each logo has to be hooped up and embroidered separately. An average club logo has 12,000 stitches, taking approximately 15 minutes to embroider. Hats have a separate attachment that needs to be fitted to the machines before they can be embroidered.
Once all the items have been embroidered, the order will be moved along to the vinyl section. This is where sponsor logos or name and number personalisation, is applied to the garment. The heat press is set at a temperature of 170 degrees and presses with a force of 60/80psi for 15 seconds. Almost 50% of items that are sold have some sort of vinyl application.
The final stage of the production chain is where the whole order is checked to ensure everything is ok to send.
After a garment has passed the quality control station, it is folded and placed back into its original packaging. Once everything is ready to go, we place the order in a grey plastic bag and put a DPD label on it ready to be collected at the end of each day.