Edge-to-edge printing for B2B merch programs in Armenia

Five structural blocks for the edge-to-edge method

1. Oversized-screen geometry, screen width, and per-colour setup fee

Every edge-to-edge order begins with screen-geometry confirmation — the supplier exposes an oversized screen that covers the full printable area of the garment. For a cotton tee, the screen is typically 35 x 45 cm or larger; for a canvas tote panel, 40 x 50 cm or larger; for a woven scarf, 50 x 180 cm or larger. Mesh count depends on substrate: 80-110 for heavy coverage on canvas, 120-160 for fine art on cotton tees, 60-90 for woven scarves. Per-colour setup fee for an oversized screen is approximately 6,000-10,000 AMD — roughly 50% higher than a standard screen because the screen fabric and exposure time are larger. Setup screens are archived for re-use on recurring apparel programs.

2. Per-piece AMD cost premium over standard screen printing

The per-piece AMD cost premium for edge-to-edge printing over standard screen printing is typically 50-100% because of the oversized screen setup, higher ink consumption, and tighter QC tolerance. Single-position edge-to-edge screen printing on a 180-200 GSM cotton tee at 50 units runs roughly 7,500-12,000 AMD per piece (vs. 3,800-6,000 AMD for standard). At 100 units, roughly 5,500-9,000 AMD (vs. 2,500-4,000 AMD). At 500 units, roughly 4,200-6,800 AMD (vs. 1,800-3,000 AMD). At 1,000 units, roughly 3,500-5,800 AMD (vs. 1,500-2,500 AMD). Sublimation-based edge-to-edge on polyester scarves runs roughly 30-50% lower than screen-based edge-to-edge on cotton.

3. Production routes across Yerevan, Istanbul, and Guangzhou

Yerevan edge-to-edge screen print shops handle 50-500 unit runs with typical lead times of 8-14 working days from production release lock. Istanbul edge-to-edge partners handle 500-2,000+ unit runs with lead times of 16-24 working days door-to-Yerevan. EAEU-routed edge-to-edge partners handle 2,000+ unit retail-export rolls with lead times of 24-32 working days door-to-Yerevan. Sublimation-based edge-to-edge on polyester runs on faster cycles (5-8 working days for 100-500 units in Yerevan) because the print-and-press workflow is simpler.

4. Pantone approximation, hand-feel, and edge-bleed QC checks

Edge-to-edge screen printing reproduces Pantone-approximation within a Delta-E tolerance band of roughly 2-4 against the Pantone reference on cotton substrates — comparable to standard screen printing. Hand-feel depends on ink load: heavy coverage at 80-110 mesh count produces a noticeable hand-feel, lighter coverage at 120-160 mesh count approaches standard hand-feel. Edge-bleed QC checks focus on substrate-edge cleanliness (no ink bleed past the seam), mark-completion at the perimeter (no missing ink at the edge of the artwork), and stitch-line clearance.

5. Defect tolerance, overrun buffer, and lifetime expectation

Armenian B2B edge-to-edge orders typically carry a 2-3% defect tolerance (higher than standard screen printing because the QC surface is larger) with full replacement at supplier cost for any unit that fails edge-bleed QC. The supplier holds a 10-15% overrun buffer on the order quantity. Edge-to-edge decorations on cotton withstand 30-50 industrial laundry cycles — slightly less durable than standard screen printing because the ink deposit is heavier and edge zones see more abrasion.

Technical specs, common pitfalls, and process workflow

Screen geometry specs, mesh counts, and ink chemistry

Edge-to-edge screen-printing specifications depend on garment type. Cotton tee geometry: 35 x 45 cm screen, 120-160 mesh count, water-based or plastisol ink at 4-8 Pa·s viscosity. Canvas tote geometry: 40 x 50 cm screen, 80-110 mesh count, heavier ink deposit. Woven scarf geometry: 50 x 180 cm screen for sublimation, 60-90 mesh count. Cure: 160-180°C for 90-180 seconds in a conveyor dryer. Sublimation cure: 200°C for 30-60 seconds in a heat press. The supplier documents screen dimensions, mesh count, ink chemistry, and cure parameters on the per-run QC log.

Common buyer pitfalls

Five pitfalls recur in Armenian B2B edge-to-edge orders. First, supplying artwork with a margin or border when full-bleed is required — the supplier exposes a screen with a margin and the artwork does not reach the seam. Second, requesting edge-to-edge on a knit or stretchy substrate — the bleed geometry distorts with stretch. Third, omitting the substrate-edge clearance spec — the artwork bleeds past the seam and the seam allowance is contaminated. Fourth, expecting Pantone-accurate colour reproduction on a heavy-coverage edge-to-edge print — Delta-E tolerance widens to 3-5 on heavy coverage. Fifth, omitting edge-bleed QC from the brief — the supplier's default QC does not include perimeter checks.

Process workflow in a Yerevan edge-to-edge run

A typical Yerevan edge-to-edge workflow runs six stages. First, screen-geometry confirmation and oversized-screen exposure (1-2 days). Second, garment receipt and pre-press flattening (half-day). Third, edge-to-edge print run with per-position QC checks including edge-bleed verification (3-5 days for 100-500 units). Fourth, cure in a conveyor dryer at 160-180°C (1-2 hours per batch). Fifth, edge-bleed QC and final QC (half-day to one day). Sixth, fold, premium pack, and ship (half-day). The full cycle takes 7-12 working days plus the 1-2 day buffer for delivery to named Yerevan addresses.

Anonymised case study: premium campaign tee

An Armenian tourism-board-adjacent campaign wanted a premium campaign tee with a panoramic landscape full-bleed print. The buyer supplied a 300 DPI TIFF at full-bleed dimensions. The supplier exposed an oversized 40 x 50 cm screen, ran 250 cotton tees through a Yerevan edge-to-edge shop in 10 working days, delivered to a named Yerevan address. Per-piece cost was roughly 9,500 AMD including the oversized-screen setup, water-based ink, and premium packaging. The buyer re-ordered 600 units the following season with a refined landscape artwork and shifted production to an Istanbul shop at roughly 6,800 AMD per piece.

Compliance: OEKO-TEX, GOTS, and edge-bleed QC documentation

Edge-to-edge orders carry the same compliance documentation as standard screen-print orders with one addition: a per-run edge-bleed QC log documenting substrate-edge cleanliness, mark-completion at the perimeter, and stitch-line clearance. OEKO-TEX Standard 100 on substrate is the minimum requirement. GOTS certification applies if organic cotton is claimed. OEKO-TEX-certified water-based ink systems are the default chemistry; plastisol is acceptable on cotton-poly blends with phthalate-compliance documentation. The supplier's edge-bleed QC log is the documentation layer that ties edge-to-edge quality to the certification regime.

Edge-to-edge vs standard screen printing: when to choose each

Edge-to-edge printing and standard screen printing are complementary decoration methods, not substitutes. Edge-to-edge is the right choice when the artwork is photographic and intended to bleed off the substrate, when the buyer markets a premium or campaign-driven apparel program, when the garment is a tote or scarf where the entire surface is the canvas, or when the buyer wants a repeating pattern across the garment. Standard screen printing is the right choice when the buyer wants a primary chest or centre-front mark as the dominant decoration, when the per-piece cost is the dominant decision criterion, or when the artwork is a brand identity mark that does not need full-bleed. Most Armenian B2B buyers reserve edge-to-edge for premium campaign apparel and retail totes/scarves.

End-of-life and recycling routes

Edge-to-edge apparel is recyclable through textile recycling centres in Yerevan and the marzes; cotton fibres are recovered and re-spun for lower-grade textile applications. Edge-to-edge ink chemistry matches standard screen-print chemistry and does not introduce additional recycling constraints. Edge-bleed marks are easier to identify visually at the recycling-sorting stage because the full-bleed geometry is distinctive. Final collection transport is managed by the buyer through the recycling centre or textile processing partner.

Frequently asked questions