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Smart strategies to maximize ROI with your Sawgrass system

When you invest in a Sawgrass printer, you are investing in business growth. Whether you print custom t-shirts, mugs, keychains, or promotional products, one goal drives profitability: reduce waste, improve efficiency, and increase profit.

In this workshop recap, Sawgrass Education Manager Rhonda shares simple, practical strategies to help you improve your return on investment by reducing waste across your workflow, from design to printing to pressing.

Why reducing waste matters for ROI

Every reprint costs money. It also costs time you could spend fulfilling orders. Reprints can use:

When you reduce waste, you improve your ROI because you:

If you want to reduce waste and increase profit with Sawgrass, start by tightening the steps that cause the most reprints.

Why choose Sawgrass in the maker market

If you are comparing Sawgrass with Epson or other options, consider what matters when you are running a customization business. You need consistent output and a repeatable workflow that helps you deliver sellable results without constant trial and error.

Sawgrass is built for decoration and production workflows. That helps you reduce waste, avoid reprints, and protect your margins as you grow.

Use ganging and nesting to maximize paper usage

One of the easiest ways to reduce sublimation paper waste is by using ganging and nesting in the Sawgrass Print Utility. You fit more designs on each page and cut down on unused space.

What is nesting

Nesting means placing multiple copies of the same design on one sheet.

Use nesting for small items like:

Ways nesting reduces waste:

What is ganging

Ganging means placing different designs on the same page, as long as they are going onto the same type of product so the color profile matches.

Example:

This works well for small batch orders and mixed custom sets.

Bonus tip: use the Recents folder

The Sawgrass Print Utility saves jobs in your Recents folder. That means you can open and reprint without rebuilding layouts. Less setup time supports higher profit.

Choose high quality blanks to avoid costly reprints

Cheap blanks often lead to uneven results, which leads to reprints. Low quality blanks can cause:

High quality sublimation blanks are designed for sublimation and typically provide more consistent coatings and more reliable transfers. When blanks fail, you waste the blank, the paper, the ink, and your time.

Blanks where quality matters most include:

Be smart about fabric choices, especially for VersiFlex

If you are using VersiFlex or pressing cotton garments, watch for fabrics that shift during pressing. Some dyes react to heat and can create inconsistent results.

Common trouble spots include:

If you see color shifting, test another brand before producing a full order.

Pro tip: keep scrap fabric for testing

Testing on scrap reduces waste. Keep:

Keep your Sawgrass printer turned on

This is a built-in way to reduce waste. Sawgrass printers perform automatic self-maintenance cycles every 10 to 12 hours when not actively in use.

These cycles help keep ink moving. When ink sits too long, particles can settle, lines can clog, and print quality can suffer. Poor print quality often leads to reprints.

Best practices:

Printers left off for long periods are more likely to develop clogging issues.

Always check ink expiration dates

Expired ink can increase the risk of:

Using in-date Sawgrass ink helps protect print quality, printer health, and your profit margin.

Use the Sawgrass ROI calculator to set sales goals

Want to estimate how quickly your printer can pay for itself? Use the Sawgrass ROI Calculator on the Sawgrass website.

Example goals:

Reducing waste plus steady production can shorten your payoff timeline.

Small changes that create big profit

Here is a quick recap of how to reduce waste and increase profit with Sawgrass:

Every sheet of paper saved and every reprint avoided improves ROI.

Final thoughts

Reducing waste is about more than efficiency. It is about protecting your margins. When you print smarter, use quality materials, and maintain your equipment properly, you protect your investment and grow your business faster.

Ready to reduce waste and increase profit with Sawgrass? Start with your next print job.

Need help

The Sawgrass Education Team is here to support you.

Adding the Sawgrass VersiFlex system to my workspace at BGC Endless Creations has been a total game-changer for my embroidery business.


I’ve always loved appliqué embroidery, and cotton is my favorite fabric to stitch on. But finding the perfect shade or pattern in stores can be surprisingly hard—especially when a customer wants a very specific color match.

With VersiFlex, I can create the look I need on demand. I design the artwork, print it, press it onto cotton, and then stitch my appliqué like usual. That means I can match colors and patterns for each order without hunting all over town for “close enough.”

What’s surprised me most is how much I’ve been able to expand beyond embroidery materials. With the right workflow, VersiFlex opens the door to decorating natural fabrics (like cotton) as well as uncoated surfaces like wood and stone—and I can still create classic sublimation projects like mugs and tumblers when I want to. 

My workflow now looks like this:

Design → Print → Press → Peel → Stitch.

It’s fast, consistent, and the transfers are easy to work with—no trimming or weeding around the design. 

Before VersiFlex, I spent so much time searching for the right fabric color or pattern. Now I spend that time creating. I can deliver more personalized projects, turn orders around faster, and confidently say “yes” to ideas that used to feel out of reach.

For my small business, that’s everything. If you’re a small business owner, a creative entrepreneur, or you love making custom projects, VersiFlex is absolutely worth a look.

Bring nostalgic charm to your holiday décor with a Holly Jolly Vintage Santa Canvas Print!  

Featuring a classic Santa design and warm, heritage-inspired details, this project captures the spirit of Christmas past. With Sawgrass VersiFlex, you can easily create a high-quality canvas print that adds timeless cheer to any space. 

Skill Level: Beginner 

Tools & Supplies: 

How To Create It: 

  1. Click the DESIGN button on your MySawgrass dashboard. 
  1. Select Custom Canvas: Rectangle 7.25” x 11.25” 
  1. Select Your Design: Holly_Jolly_Vintage_Santa_Canvas 
  1. Size to fit canvas.  
  1. Send your ready to design to print utility by clicking PRINT. 

How To Print It: 

  1. Select your ready printer loaded with Sawgrass VersiFlex inks. 
  1. Select the Canvas preset, or select Natural Fabrics (Burlap, Canvas Linen) as the product. 
  1. Load printer with VersiFlex Light paper. 
  1. Click Print. 

How To Press It: 

  1. Position your fabric onto the base of your heat press. 
  1. Prepress your fabric for 10-15 seconds to release moisture. If you see steam when releasing the press, press again until the steam disappears. 
  1. While the print is still slightly tacky, place your print face down onto the center of the fabric. Do not reposition your print once you have it placed. 
  1. Place a piece of protective blowout paper over your print to protect your heat press from any excess ink. 
  1. Press for 30 seconds at 375°F at high pressure. 
  1. When the timer sounds, open your press and peel your print immediately. Delayed peeling will cause the paper to stick. 
  1. Place the blowout paper back over the printed fabric and press for another 10 seconds to seal the print. 

Tips & Tricks 

Showcase your holiday memories with a Merry & Bright Tree Photo Panel on metal! Featuring vibrant, festive designs and a sleek finish, this panel adds a modern, durable touch to your décor. 

 

Skill Level: Beginner 

Tools & Supplies: 

How To Create It: 

  1. Click the DESIGN button on your MySawgrass dashboard. 
  1. Select Custom Canvas: 8” x 10” with .125” bleed 
  1. Select Your Design: Merry_Bright_Tree_Photo_Panel 
  1. Size to fit canvas. 
  1. Send your ready to design to print utility by clicking PRINT. 

How To Print It: 

  1. Select your ready printer. 
  1. Select Metal as the product. 
  1. Load printer with Truepix Classic Paper 
  1. Click Print. 

How To Press It: 

  1. Place your print face up on a table or a secure work surface.  
  1. Place the panel face down onto the print. 
  1. Secure with heat-resistant tape. 
  1. Carefully flip and place on the base of the press paper side up. 
  1. Place a piece of protective blowout paper under your product to protect your heat press from any excess ink. 
  1. Press for 60 seconds at 400°F at high pressure. 
  1. When the timer sounds, open your press and peel your print. Be careful, product will be hot. Use a glove or let the product cool before peeling. 

Light up the season with a Merry & Bright Lights Tumbler! Featuring bold, festive designs inspired by holiday lights, this tumbler is perfect for sipping in style. Easily personalize it for a vibrant, durable, and merry addition to your holiday collection. 

Skill Level: Intermediate 

Tools & Supplies: 

How To Create It: 

  1. Click the DESIGN button on your MySawgrass dashboard. 
  1. Select Product: 10oz Stainless Steel Lowball Tumbler 
  1. Select Your Design: Merry_Bright_Lights_Tumbler 
  1. Size to fit canvas, personalize with your initial. 
  1. Send your ready to design to print utility by clicking PRINT. 

How To Print It: 

  1. Select your ready printer. 
  1. Select Stainless Steel as the product. 
  1. Load printer with Truepix Classic Paper 
  1. Click Print. 

How To Press It: 

  1. Trim your paper down to the print area. 
  1. Wrap your paper around the tumbler with print side facing the mug. 
  1. Secure with heat-resistant tape. 
  1. Place your tumbler into your mug press and press. 
  1. Press for 60-90 seconds at 365°F 
  1. When the timer sounds, open your press and peel your print. Be careful, product will be hot. Use a glove or let the product cool before peeling. 

Add a modern twist to your holiday décor with a Merry & Bright Geometric Frame! Featuring bold shapes and festive colors, this project is perfect for showcasing your favorite seasonal memories.  

Skill Level: Beginner 

Tools & Supplies: 

How To Create It: 

  1. Click the DESIGN button on your MySawgrass dashboard. 
  1. Select Product: 8” x 10” MDF Picture Frame 
  1. Select Your Design: Merry_Bright_Geometric_Frame 
  1. Size to fit canvas. 
  1. Send your ready to design to print utility by clicking PRINT. 

How To Print It: 

  1. Select your ready printer. 
  1. Select MDF Board as the product. 
  1. Load printer with Truepix Classic Paper 
  1. Click Print. 

How To Press It: 

  1. Place your print face up on a table or a secure work surface.  
  1. Place the frame face down onto the print. 
  1. Secure with heat-resistant tape. 
  1. Carefully flip and place on the base of the press paper side up. 
  1. Place a piece of protective blowout paper under your product to protect your heat press from any excess ink. 
  1. Press for 60 seconds at 400°F at high pressure. 
  1. When the timer sounds, open your press and peel your print. Be careful, product will be hot. Use a glove or let the product cool before peeling. 

Add festive charm to your home with a Holly Jolly Custom Tree Pillow!  

Personalize it with your family name using Sawgrass VersiFlex, creating a cozy, cheerful accent that makes your holiday décor truly one-of-a-kind. 

Skill Level: Intermediate 

Tools & Supplies: 

How To Create It: 

  1. Click the DESIGN button on your MySawgrass dashboard. 
  1. Select Product: 15.75” Linen Pillow Cover – Full Print 
  1. Select Your Design: Holly_Jolly_Custom_Tree 
  1. Size to fit canvas, personalize with your family name. 
  1. Send your ready to design to print utility by clicking PRINT. 

How To Print It: 

  1. Select your ready printer loaded with Sawgrass VersiFlex inks. 
  1. Select the Burlap, Canvas, Cotton or Linen preset based on your pillow, or select Cotton or Natural Fabrics (Burlap, Canvas Linen) as the product. 
  1. Load printer with VersiFlex Light paper. 
  1. Click Print. 

How To Press It: 

  1. Position your pillow onto the base of your heat press. 
  1. Prepress your fabric for 10-15 seconds to release moisture. If you see steam when releasing the press, press again until the steam disappears. 
  1. While the print is still slightly tacky, place your print face down onto the center of the pillow. Do not reposition your print once you have it placed. 
  1. Place a piece of protective blowout paper over your print to protect your heat press from any excess ink. 
  1. Press for 30 seconds at 375°F at high pressure. 
  1. When the timer sounds, open your press and peel your print immediately. Delayed peeling will cause the paper to stick. 
  1. Place the blowout paper back over the printed fabric and press for another 10 seconds to seal the print. 
  1. Stuff final pillow with a pillow insert or pillow stuffing. 

Tips & Tricks 

Sip in holiday style with a Gingerbread Village 15oz Mug! Featuring charming, festive designs straight out of a gingerbread village, this mug is perfect for cozying up with your favorite seasonal drink or gift for a cheerful, one-of-a-kind holiday treat. 

Skill Level: Beginner 

Tools & Supplies: 

How To Create It: 

For the 15oz Mug 

  1. Click the DESIGN button on your MySawgrass dashboard. 
  1. Select Product: 15oz Ceramic Mug 
  1. Select Your Design: B201D_Gingerbread_Village_Mug 
  1. Size to fit canvas. 
  1. Send your ready to design to print utility by clicking PRINT. 

For The 11oz Mug: 

  1. Click the DESIGN button on your MySawgrass dashboard. 
  1. Select Product: 11oz Ceramic Mug 
  1. Select Your Design: B101D_Gingerbread_House_Mug 
  1. Size to fit canvas. 
  1. Send your ready to design to print utility by clicking PRINT. 

How To Print It: 

  1. Select your ready printer. 
  1. Select Ceramic as the product. 
  1. Load printer with Truepix Classic Paper 
  1. Click Print. 

How To Press It: 

  1. Trim your paper down to the print area. 
  1. Wrap your paper around the mug with print side facing the mug. 
  1. Secure with heat-resistant tape. 
  1. Place your mug into your mug press and press. 
  1. Press for 150-300 seconds at 350-400°F 
  1. When the timer sounds, open your press and peel your print. Be careful, product will be hot. Use a glove or let the product cool before peeling. 

Serve up some holiday fun with Gingerbread Cookie Coasters! These festive coasters look good enough to eat with the adding a sweet, decorative touch to your holiday table. 

Skill Level: Intermediate 

Tools & Supplies: 

How To Create It: 

  1. Click the DESIGN button on your MySawgrass dashboard. 
  1. Select Product: Leather Round Coaster 
  1. Select Your Element: Gingerbread_Round_Cookie_01, Gingerbread_Round_Cookie_02 
  1. Size to fit canvas. 
  1. Send your ready to design to print utility by clicking PRINT. 

How To Print It: 

  1. Select your ready printer. 
  1. Select Vegan Leather as the product. 
  1. Load printer with Truepix Classic Paper 
  1. Click Print. 

How To Press It: 

  1. Place your print face up on a table or a secure work surface.  
  1. Place the leather coaster face down onto the print. 
  1. Secure with heat-resistant tape. 
  1. Carefully flip and place on the base of the press paper side up. 
  1. Place a piece of protective blowout paper under your product to protect your heat press from any excess ink. 
  1. Press for 30 seconds at 375°F at medium pressure. 
  1. When the timer sounds, open your press and peel your print. Be careful, product will be hot. Use a glove or let the product cool before peeling. 

Tips & Tricks 

Create a festive touch for every member of the family with a Holly Jolly Initial Stocking!  

Featuring cheerful holiday designs and a personalized monogram, this project is the perfect blend of classic and custom. Made with Sawgrass VersiFlex, it’s easy to add bright, durable details that make your mantel merry and bright. 

Skill Level: Advanced 

Tools & Supplies: 

How To Create It: 

For The Cuff: 

  1. Click the DESIGN button on your MySawgrass dashboard. 
  1. Select Custom Canvas: Rectangle 2.75” x 2” 
  1. Select Your Design: Holly_Jolly_Initial 
  1. Size to fit canvas, personalize with your desired initial. 
  1. Send your ready to design to print utility by clicking PRINT. 

For The Foot: 

  1. Click the DESIGN button on your MySawgrass dashboard. 
  1. Select Custom Canvas: Rectangle 10.75” x  10.5” 
  1. Select Your Design: Holly_Jolly_Laurel_Stack 
  1. Size to fit canvas. 
  1. Send your ready to design to print utility by clicking PRINT. 

How To Print It: 

For The Cuff: 

  1. Select your ready printer loaded with Sawgrass VersiFlex inks. 
  1. Select the Burlap preset, or select Natural Fabrics (Burlap, Canvas Linen) as the product. 
  1. Load paper with VersiFlex Light paper. 
  1. Click Print. 

For The Foot: 

  1. Select your ready printer loaded with Sawgrass VersiFlex inks. 
  1. Select the Burlap preset, or select Natural Fabrics (Burlap, Canvas Linen) as the product. 
  1. Load printer with VersiFlex Light paper. 
  1. Click Print. 

How To Press It: 

For The Cuff: 

  1. Position the top of your stocking onto the base of your heat press. 
  1. Prepress your fabric for 10-15 seconds to release moisture. If you see steam when releasing the press, press again until the steam disappears. 
  1. While the print is still slightly tacky, place your print face down onto the center of the cuff. Do not reposition your print once you have it placed. 
  1. Place a piece of protective blowout paper over your print to protect your heat press from any excess ink. 
  1. Press for 30 seconds at 375°F at high pressure. 
  1. When the timer sounds, open your press and peel your print immediately. Delayed peeling will cause the paper to stick. 
  1. Place the blowout paper back over the printed fabric and press for another 10 seconds to seal the print. 

For The Foot: 

  1. Position the sock of your stocking onto the base of your heat press. 
  1. Prepress your fabric for 10-15 seconds to release moisture. If you see steam when releasing the press, press again until the steam disappears. 
  1. While the print is still slightly tacky, place your print face down onto the foot with the corners of the middle holly laurel angled to touch the inside curve and outside heel of the foot. Do not reposition your print once you have it placed. 
  1. Place a piece of protective blowout paper over your print to protect your heat press from any excess ink. 
  1. Press for 30 seconds at 375° at high pressure. 
  1. When the timer sounds, open your press and peel your print immediately. Delayed peeling will cause the paper to stick. 
  1. Place the blowout paper back over the printed fabric and press for another 10 seconds to seal the print. 

Tips & Tricks: 

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