In the fast-growing Turkish textile industry, mid-size garment factories face intense pressure to deliver high-quality custom prints quickly while controlling production costs. Traditional screen printing demands large minimum orders and lengthy setup, making it unsustainable for the rising wave of e-commerce small-batch orders. A garment factory in Istanbul turned to FUJIA Dual-Head A1 DTF Printer — and increased order throughput by 40%, cut production costs by 30%, and shortened delivery time from 7 days to under 3 days.
| Location | Turkey |
| Product | FUJIA A1 Dual-Head DTF Printer (Model 02) |
| Industry | Garment Manufacturing & Print-on-Demand |
| Applications | T-shirts, hoodies, sportswear, fashion accessories, promotional textiles |
| Objective | Reduce outsourcing dependency, enable fast small-batch production, improve margins |
Customer Background
The customer is a mid-sized garment factory based in Istanbul, Turkey — one of Europe’s largest textile hubs. The factory produces custom apparel for domestic retail brands, online marketplaces, and export buyers across Europe and the Middle East. With over 15 years in the textile trade, the factory had built a solid reputation for quality, but its analog printing workflow was holding it back from capturing the fast-growing print-on-demand segment.
Challenges
- High Minimum Orders – Screen printing required 200+ pieces per design, shutting out small-batch clients.
- Slow Setup Time – Screen creation and color registration took hours per design — too slow for sampling and rush orders.
- Outsourcing Bottlenecks – DTF orders were outsourced to third-party print shops, causing unpredictable turnaround and quality variance.
- Shrinking Margins – Outsourcing ate 40% of the profit margin on custom orders.
- Seasonal Demand Swings – During peak seasons (spring/summer collections), the factory couldn’t scale fast enough to meet deadlines.
Solution: FUJIA A1 Dual-Head DTF Printer
FUJIA recommended the A1 Dual-Head DTF Printer (Model 02) — a high-speed industrial direct-to-film solution purpose-built for mid-volume garment production. The printer was installed on-site, allowing the factory to bring all custom printing in-house for the first time.
- 65cm (A1) print width handles standard garment panel sizes in a single pass
- Dual Epson I3200 printheads deliver 4–6 m²/hr at production-grade resolution
- Honson mainboard + Leadshine servo + THK silent linear guide ensure rock-solid registration for multi-color designs
- Integrated powder-shake-and-cure workflow — print, powder, cure, press, all in one seamless line
- Zero outsourcing: factory gained full control over quality, speed, and cost
Product Specifications
| Specification | FUJIA A1 Dual-Head DTF Printer (Model 02) |
|---|---|
| Print Width | Up to 650 mm (25.5 in) — A1 |
| Printheads | 2 × Epson I3200 / I1600 / XP600 (factory-configured) |
| Print Speed (6Pass) | 4–6 m²/hr |
| Resolution | 720 × 1200 dpi (4Pass) to 720 × 2400 dpi (8Pass) |
| Ink Type | DTF Pigment Ink (CMYK + White) |
| Media | PET Transfer Film |
| Transmission | Honson mainboard, Leadshine servo, THK silent guide rail |
| Application Fabrics | Cotton, polyester, blends, canvas, denim, nylon |
Key Advantages
- In-House Production Control – No more outsourcing. The factory controls every job from artwork to finished garment.
- Zero Minimum Orders – Accept single-piece and small-batch orders that were previously impossible with screen printing.
- Fast Turnaround – From file to finished print in under 30 minutes — 3-day delivery instead of 7+ days.
- Industrial-Grade Stability – Honson-Leadshine-THK transmission stack means 12-hour continuous runs without quality drift.
- Dual Printhead Redundancy – Two I3200 heads share the workload, doubling throughput and providing fail-safe operation during peak season.
Results & Customer Feedback
Before vs. After — At a Glance
| Metric | Before FUJIA DTF | After FUJIA DTF | Change |
|---|---|---|---|
| Order Processing Efficiency | Baseline | 1.4× throughput | 🔺 +40% |
| Production Cost | 100% (with outsourcing) | 70% (in-house) | 🔻 -30% |
| Average Delivery Time | 7 days | 2.5 days | 🔻 -64% |
| Small-Batch Capability | 0% of revenue | 60% of revenue | 🔺 New Stream |
“We used to turn away small-batch clients because screen printing wasn’t cost-effective, and outsourcing was eating our margins. With FUJIA’s A1 DTF printer installed in-house, we reversed that — small orders are now our fastest-growing revenue stream. The machine runs reliably all day, and our delivery time dropped from a week to 2–3 days. For a mid-size factory like ours, this was exactly the upgrade we needed.”
— Production Manager, Istanbul-based Garment Factory
*Client identity withheld per NDA. All performance figures verified by FUJIA post-installation support audit. Results may vary based on order volume, operator skill, and production environment.
Turkish garment industry data referenced from Grand View Research digital textile printing market.
