Case Studies


YOGA TOWELS

Challenge: Client approached FIEL for decorated terry yoga towels. It was an 8 colour print job with 2,500 pieces to be completed in 3 days.

Solution: Microfiber terry towel with screen print was the way to go with this order. It offers consumers a variety of imprint possibilities such as bold print color options. To ensure the colors did not smudge, precise calibration on the screen printing machine was required. It was a delicate process to choose a screen that allowed the ink to be printed on the fabric without compromising the details of the design and the color.

Result: The towels turned out great with a crisp finish to every design on each towel. The client was very pleased with the results. test2

SKU: YOG_MFT18

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SUBLIMATION ON C-COVER

Challenge: Distributor needed branding ideas for their client, Direct TV. It was a rush order with only three days to complete the entire order, from doing the samples to cutting the product,adding the imprint and finally sewing it.

Solution: To accommodate clients needs as per their specification, Silken C-cover was the way to go with this order. Sublimation was done for this job. The image was sublimated over the cut panels edge to edge, then the finishing was done.
Having the production and printing done in-house, enables Fiel to adjust processes and deal with unexpected issues with minimal delays.

Result: The customer was very happy with the end product.

SKU: Custom Seat Cover

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HEAT TRANSFER ON WRISTBANDS & HEADBANDS

Challenge: Stampede City and other gymnastics club have recently been putting orders through for terry wristbands and headbands from FIEL. They want it to be decorated with their logo so it can be used for various events.

Solution: Adding imprints to a terry wristband and/or headband would be difficult since the logo of the company can get deformed when the fabric is stretched. A special form of heat transfer was used for the wristbands and headbands. The logo would not look distorted when the fabric is stretched and having that type of heat transfer also shows finer details in the logo.

Result: The logo on the wristbands and headbands looked great and the clients were pleased with their orders.

SKU: 3WB & 2HB

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HOCKEY CHAMPIONSHIP PEEWEE

Challenge: Client wanted Pennants for a hockey championship with an extremely tight deadline. The persistence of FIEL’s sales representative paid off and the order was placed. However, FIEL had 24 hrs to produce the order.

Solution: In order to produce the pennants in a timely manner, excellent communication and service of FIEL sales representative with the distributor paid off. Randy, a FIEL sales rep said to the distributor, "Normally the takes approx 5 days, but we will get it ready for you tomorrow, if order is placed within the hour. It will be manufactured and shipped from FIEL Toronto, Ontario. Please email your purchase order to orders@fiel.com for the quickest processing". The order received by the distributor, manufactured and shipped by the FIEL team within 24 hrs, as promised to the client.

Result: The distributor was very happy and this is what they said, "Hi Randy, I finally have a minute. Thank you so much for the quick turnaround on the pennants. They turned out perfect. Here's a picture of what I used them for. Thanks again."

Proper planning and execution of the workflow was crucial to the success of meeting the project deadline. Pennants are a great event promo product for hockey tournaments.

SKU: PF02

 

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EMBROIDERY ON FLEECE NECK CUSHION

Challenge: Client approached FIEL for wanting embroidery done on fleece neck cushions which is a complicated process that requires panels.

Solution: Since there have been orders like this before with other fleece products, it was a walk in the park for the production and artwork staff at FIEL. Manufacturing and in-house embroidering reduced the delay on the product since the panels for the product can be developed in-house Due to the restricted size of the embroidery hoops, all decorations must be done on panels prior to the completion of the product. The advantage of having all processes under one roof was clearly demonstrated for this job.

Result: The embroidered neck cushions turned out great.

SKU: FNC12

 

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KIDS SUPER HERO CAPES

Challenge: Distributor needed branding ideas for their client, Grand Canyon University Foundation. The idea was to use the product in their event which recognized cancer survivors. It was a rush order with only three days to complete the entire order, from doing the samples to cutting the product to sewing it and finally adding the imprint.

Solution: To accommodate clients needs as per their specification, kids poplin super hero capes was the way to go with this order. Screen printing was done for this job. Having the production and printing done in-house, enables Fiel to adjust processes and deal with unexpected issues with minimal delays.

Result: The client was satisfied with how the capes turned out and the end users were very happy with the quality of the cape. This is what they had to say "Thank you for helping to make this happen. The Foundation appreciates it as well. Here are a few pictures of the event".

SKU: KDCP01

 

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SANTA HATS & STOCKINGS

Challenge: During the Christmas seasons, clients wanted Santa hats and stockings with a variety of decoration requests.

Solution: We offered three decoration methods: screen printing, heat transfer printing, and embroidery. To suit every clients’ unique needs and requests, the appropriate decoration method can be chosen. For simpler designs and maintaining a soft feel, screen printing is ideal. More complex designs or even photographs benefit from heat transfer printing. FIEL uses transfer media that can mimic the feel of a screen print despite being a digital transfer. Lastly, embroidery is for the clients that prefers a clear distinction between the fabric and design. Instead of the artwork being composed of ink or transfer media, the design is conveyed in traditional and quality stitching.

Result: Each decoration method has its merits.

SKU: INFXHAT, XSOCK17

 

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EMBROIDERY ON 2 SIDES, REVERSIBLE HEADBAND FHB24

Challenge: Client chose our reversible headband and wanted embroidery done to both sides. This meant decoration must be done on panels prior to the finishing of the product.

Solution: Manufacturing and embroidering in-house reduced the delay if panels had to be sent to the embroiderer. In this case, it would have been further complicated because the product would have needed to return to us, the manufacturer, for the finishing after the panels are embroidered. The advantage of having all processes under one roof was clearly demonstrated for this job.

Result: Client praised the quick turnaround and loved the reversible product.

SKU: FHB24

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DISCHARGED PRINTING IN 3 LOCATIONS GIVING FULL COVERAGE

Challenge: Client requested screen printed towels with artwork in three different locations. The towels chosen were grey and the artwork is lighter in color.

Solution: To prevent compromising the feel of the towel, discharge printing was performed instead of putting a white base on the fabric prior to screen printing the artwork. Considering the artwork consisted of three multi-color designs and each one was printed in a separate location, this job was essentially three orders combined into one.

Result: Despite the amount of labor involved with a job such as this, the order was completed efficiently and the designs are printed effectively because of discharge printing.

SKU: VTWL500

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HEAT TRANSFER ON SCARVES

Challenge: Client approached FIEL for a large quantity of fleece scarves with a two-location heat transfer.

Solution: The artwork being transferred has a white background which is in contrast to the black fabric of the scarves. In order to prevent the black background of the fabric from seeping into the foreground, it is crucial the transfer media properly blocks all color except for what is part of the artwork. There are two types of transfer media that FIEL uses for heat transfer and we opted for the thicker of the two. This media type provides an excellent surface for the digital transfer and effectively blocks the color of the dark background.

Result:
 The artwork shows no muted colors and looks especially attractive given the contrast.

SKU: SCV59

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TRANSFER MEDIA

Challenge: Client chose a dark apron and wanted a heat transfer that has a similar feel to a screen print.

Solution: When applying a heat transfer to dark fabric, there is a subtle but noticeable outline where fabric meets the edge of the transfer media. This is a point both the manufacturer and customer understands. However, the request for a heat transfer that feels like a screen print presented an opportunity to use a different type of transfer media. Compared to the standard one, this was a thinner media that would comply with the customer’s request for a softer feel and minimize the “halo” effect of the heat transfer process.

Result:
 It was a coincidence but it is fitting to say the opportunity was killing two birds with one stone.

SKU: BA55

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EMBROIDERED MITTENS

Challenge: Embroidery on mittens. Embroidery is not possible on finished mittens because of restrictions to the embroidery hoop size.

Solution: Due to restricted size of the embroidery hoops, mittens cannot be hooped for embroidery as finished goods. Panels are required first for any form of decoration on mittens (embroidery, silk screen, heat transfer or sublimation). Once the decoration is completed, panels were then moved to production for finishing. Having the production and decoration in-house enabled us to adjust processes and deal with unexpected issues with minimal delays.

Result: Embroidered mittens turned out great and client was very happy.

SKU:
 MIT20

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DISCHARGE PRINTING

Challenge: Client requested decorated car seat covers: a red imprint on a black surface. When printing on dark fabrics, it is advised to do a white base where the design will be in order to accentuate its colors. However, this means putting an extra layer of ink which can compromise the softness of the fabric.

Solution: Discharge printing was used to lessen the amount of ink that needed to be used. Instead of printing a white base, a discharging agent was mixed with the ink for the design and printed directly onto the fabric. One drawback of using this method is it only works on 100% cotton. A low screen mesh was used to allow copious ink to saturate the fabric. When put through the dryer, the heat caused the discharging agent to remove the original dyes of the fabric and replace it with the color that it was mixed with.

Result: The discharging agent proved to be a success as can be seen by the bright red color of the design. The added advantage of using it is the absence of the white base so the fabric maintained its soft feel.

SKU: VCOVER01

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OUR CAPABILITY ON TABLETHROWS / TABLE RUNNER

For decorating tablecloths and table runners, FIEL currently uses two methods:
screen printing and heat transfer printing.

Screen printing utilizes screen meshes and water-based inks to decorate the fabric. This process is ideal for logos and less complicated artworks. With the help of an automatic press, the output is substantially greater than a manual press. The additional functions of the press allows for greater control so minute adjustments can be made during the printing process. Capabilities are also improved such as reducing prep time for printing in more than one location. In summary, the accuracy and precision of the printing process is increased.

The second method is heat transfer printing. Compared to screen printing, heat transfer is able to accommodate much more detailed artwork. The artwork is first printed on transfer paper and a heat press is used to adhere the artwork to the fabric.

FIEL has plans to expand decoration options and the next method that will be available in the future is embroidery.

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TB156 TABLETHROW - 2 LOCATION PRINT

Challenge: Client requested tablecloths with a two-location screen print. The main concern is ensuring the decorations are in the same position for every tablecloth.

Solution: Our automatic press is equipped with laser pointers that show the reference point in which the decoration is meant to be. This reduced possible alignment issues between the decorations and assured the tablecloths were essentially copies of one another.

Result: A simple design works! 

SKU: TB156

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FLEECE TALLY TOWEL - 7 COLOR JOB

Challenge: Client approached FIEL for decorated fleece rally towels. There were four designs provided by the client and each was to be printed onto a thousand towels. Each design had different colors and the number of colors that were required varied.

Solution:
 Preparation was key in this project. To ensure conflicting colors did not overlap and smudge, precise registration and calibration were required. The automatic press contributed greatly to this. Selecting the proper screen mesh also affected the overall quality of the decoration process because fleece is a difficult fabric to print on. It was a delicate exercise to choose a screen mesh that allowed for ink to be printed on the surface of the fabric without compromising the details of the design.

Result:
 Please see the pictures below. 

SKU: FLC1010

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4-COLOR PRINT INCLUDING BASE

Challenge: Client ordered decorated bags made out of twill, a blend of polyester and cotton. The artwork was a light color to be printed on a dark surface. Dyed polyester, when heated, tends to bleed from the material. In this case, the dark blue color of the fabric will seep into the white finish.

Process:
 A specialized low bleed polyester white ink was used to combat this problem. This ink blocks the gaseous dye of the fabric from seeping into it. Poly-blocking inks tend to be thicker and more difficult to work with. Therefore, a screen with lower mesh size was used to print the base layer. However, the decoration process required screens of different mesh sizes in order to retain the details of the design. Correct judgement was the determining factor on whether or not this decoration job is considered successful.

Result: 
The pictures show a crisp design and a sharp contrast between the colors. That is the answer for the above question.

SKU: DUFF003

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SOFT HAND WATER BASE PRINTING

Challenge: Client had an extremely detailed artwork that was to be imprinted on a large quantity of cotton tea towels. Printing such an intricate design is not the norm for any printer in North America and most will shy away from printing a detailed print such as this.

Process:
 In order for the mesh screen to hold the details of the provided artwork, a screen with a higher mesh count was used. FIEL also used a new generation of water-based inks that make it less susceptible to dry on a screen with a higher mesh count. This retains the original detail of the artwork without having to constantly wash the screen.

Result:
 As can be seen in the pictures, the results were outstanding.

SKU: HTWL32

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5 COLOR PRINT C-APRON

Challenge: Client wanted a large quantity of custom aprons with an extremely tight deadline. The persistence of FIEL’s sales representative paid off and the order was placed. However, FIEL had 5 business days to produce 2,500 custom-made aprons with a 5-color imprint.

Process:
 In order to produce the aprons in a timely manner, the workflow had to be precise. Fabric was cut and readied for printing before sewing the final product. FIEL’s automatic press greatly reduced the time needed to print and kept the process consistent throughout. On the other hand, production staff worked diligently to match the output of the automatic press.

Result:
 Proper planning and execution of the workflow was crucial to the success of meeting the project deadline.

SKU: C-APRON

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PRINTING 2 LOCATION

Challenge: Client approached FIEL for a towel and bag set that both had to be decorated. The towel’s imprint size exceeded our standard dimensions and the artwork for the bag was unsuited for screen printing.

Result: To accommodate the client’s request, the towel’s imprint was treated as a two-location imprint. Printing proved to be a challenge because the imprints had to be aligned. If either of the imprints were not precise, the entire decoration would appear skewed.
As for the bag, heat transfer was used for the imprint to preserve the details of the artwork.
This order was also time sensitive. FIEL has less than a week to complete this order for an event. However, with the help of the automatic press, the job was finished successfully and delivered to the client within the deadline.

Feedback: Let the pictures speak for themselves.

SKU: VTWL60C & CND512

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GLOBAL NEWS: BABY BIB

Challenge: Client looking for branding ideas for Global news. Looking for product ideas that would lead to universal audience.

Result: To accommodate clients needs as per their specification, the appropriate choice was baby bib with velcro closure. Printing was done in water based ink on white panels to increase the contrast and the bibs were finished with black trim to enhance the notice ability of the message. Having the production and printing done in-house enables Fiel to adjust processes and deal with unexpected issues with minimal delays.

Feedback: Eye-catching message was good for brand awareness.

SKU: VBBIB2

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Delta Airlines: Safety Vests

Challenge: Client looking for safety vest with edge printing and customize trimmings. The project had very tight delivery times.

Result: Safety vest. As manufacturer and an in house printer, creating custom vest with edge printing was not a problem. 3 color printing process was done on back and front panels first. Given the amount of work required for finishing and timelines, our staff had to put in extra time night and weekends, to complete the project on time.

Feedback:
 Client loved the finished product and thanked FIEL for the effort put into printing the complicated logo and for putting in extra time to finish by the deadline. (This is what we do and were happy to complete the project on time for our client).

SKU: 26NYVSAREF

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Netflix: Promotion

Challenge: Client looking for branding ideas for netflix event. Specification was product with 2 colors( red and white) to show off netflix logo. The project was on a tight schedule, needed to in hands within 5 business days.

Result:
 To accommodate clients needs as per their specification, the appropriate choice was Poplin 2-Tone Cushion. Printing was done in water based ink on white panels to increase the contrast and pillows were finished with red background to enhance the notice ability of the logo. Having the production and printing done in-house enables FIEL to adjust processes and deal with unexpected issues with minimal delays.

Feedback:
 Event was a success and eye-catching logo was good for brand awareness.

SKU: PCTC122T

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Series of Tennis Matches: Terry Workout Towels

Challenge: Client wanted slim towels for players to be used in breaks during series of tennis matches. Also, the in hands date was non- negotiable because towels needed in hands within 5 days.

Result: Terry workout towel was the perfect choice, as the towel are slim enough to go around the shoulders and long enough to wipe the sweat off. Water-based ink was used to print on the terry sports towel for a soft touch and the 2 color imprint against white towel showed off quite well. Printing done in-house enables FIEL to adjust processes and deal with unexpected issues with no delays.

Feedback: Client loved the texture of the towels and the printing was well done.

SKU: TTWL44

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Heat Transfer vs Screen Printing on Wristbands/Headbands

Challenge: Client wanted a crisp (not distorted) logo to show on wristband when stretched. Wristbands and headbands are a challenge when it comes to screen printing. Because of product's stretch property, it looses the detail of the logo when worn. This results in loosing design integrity where logos or images are broken due to stretch.

Result: Special form of heat transfer is a better form of decoration used for wristbands and headbands. It shows finer details and does not loose its design integrity details when worn(stretched).

Feedback: Heat transfer on wristband holds finer details than screen printing. It gives better and brighter finish.

SKU: 1WB

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FIFA Women’s World Cup Canada 2015

Challenge: Client approached FIEL for a custom bag capable of carrying four soccer balls and two soccer nets. Logo decorations were needed in English and French. Also, the in-hands date was non-negotiable because it was for an event in Edmonton.

Result: As an in-house manufacturer, creating custom bags were no problem. However, ensuring the capacity of the bags were adequate required deliberation of the bags’ dimensions as well as fabric usage in reflection to its cost. Despite the preparation time and rushed schedule, FIEL fulfilled the client’s needs with a product that is both functional and cost-effective.

Feedback:
 “They loved the bags,” said Karen Butler from Reward Connections.

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Prep Rally Towels: University of Ottawa

Challenge: Client wanted product ideas for a pep rally. The product must be decorated with the school logo to encourage school spirit.

Result: FIEL’s rally spirit towel was the perfect choice. Simplicity was the theme and what better way to show school spirit than light-weight towels in assorted colors with the school’s logo printed on it.

Feedback: Client was pleased because it was a simple and effective product for a prep rally.

SKU: FLC1010

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Marathon: Nike Women’s Run 15k Toronto

Challenge: Nike needed branding ideas for their marathon. The event was to celebrate women in sports.

Result: Client decided on a basic tote bag with abundant space for a two-color imprint. The printing process proved challenging because the artwork was close to the edge of the bag. To cope with this, printing was done prior to the sewing of the bags. Having the production and printing done in-house enables FIEL to adjust processes and deal with unexpected issues with minimal delays.

Feedback: Event was a success and client responded the eye-catching logo was good for brand awareness.

SKU: CND114

 

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Samsung: Team Building Retreat

Challenge: Client requested product ideas for a company’s team building retreat. Being a gift idea, it was imperative the product met high quality standards in order not to tarnish the company’s hard earned reputation.

Result: FIEL’s colored beach towels were an excellent choice. Water-based ink were used to print on the velour towel for a soft touch and the white imprint against a royal blue towel only served increased the contrast and enhance the noticeability of the logo.

Feedback: Client said the employees loved the texture of the towels and the printing was well done.

SKU: VTWL60C

 

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TV: America’s Got Talent

Challenge: NBC wanted a branding product for America’s Got Talent at Radio City. An indoor event limited the product choices. The project was on a tight schedule and therefore was a race against time.

Result: The appropriate choice were seat covers. The client wanted to customize the product with pockets for water bottles and show guides. Printing also proved to be a challenge because the logo required a seven color imprint and a two color imprint at the back. Given the amount of work that was to be done, FIEL staff had to put in extra time in the evening as well as the weekend to complete the project on time.

Feedback: Client thanked FIEL for the effort put into printing the complicated logo and for putting in extra time to finish by the deadline.

SKU: EVSEAT8

 

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