Embroidery for Logos on Polos, Caps and Workwear

About Embroidery

Embroidery is a textile finishing technique that applies motifs permanently into the carrier material with thread. Hand embroidery is one of the oldest textile techniques known to humanity (archaeological finds date back to the 3rd millennium BC). Industrial machine embroidery was invented in 1828 by Josué Heilmann; computer-controlled multi-head embroidery machines (Tajima, Barudan) have been the B2B standard since the 1980s.

Facts:

• Origin: hand embroidery since ~3000 BC; machine embroidery since 1828 (Heilmann); computer-controlled from the 1980s
• Print principle: programmed embroidery machine + polyester thread (Madeira, Gunold) + stitch density 4-7 stitches/mm²
• Materials: polos, caps, fleece jackets, workwear, hoodies; dense fabrics from ~180 g/m²
• Durability: 100+ industrial wash cycles, boil-proof to 95 °C
• Quantity: possible from 1 piece, usually economical from 10-25 pieces (volume discount on the garments from 3 pieces, 3%)
• Wikipedia: Embroidery (en.wikipedia.org) · Machine embroidery
• Thread manufacturers: Madeira · Gunold
• Machine manufacturers: Tajima · Barudan

Why ShirtStore?

• 100+ washes durability — boil-proof, industry-grade, refined.
• In-house embroidery in Berlin — no subcontractors, in-house digitisation studio.
• Volume discount on the garments from 3 pieces (3%) — automatic in the configurator; embroidery and digitisation are excluded.
• Brand portfolio — B&C Pro, Stanley/Stella, B&C and premium polo models.

What is embroidery?

Machine embroidery is a computer-controlled stitching method in which industrial embroidery machines with multiple heads stitch the motif with real polyester or viscose thread onto the textile. In the first step the logo is "digitised" — that is: from the vector or pixel file an embroidery file (DST, EMB) is created, defining every individual stitch, every thread colour and every stitch direction. The machine loads this file and stitches the motif at industrial speed. Per stitch, thread and stitch direction are set precisely so the result appears dimensionally three-dimensional.

Digitisation is a craftsmanship service per logo and size and costs €27.50-88 net depending on the embroidery area (see the price table below); it is charged on every order, including reorders. Once digitised, we keep the embroidery file on file and reuse it for reorders with the same logo. Embroidery is suitable for all fabrics dense enough to hold the thread — i.e. polos, caps, fleece, sweatshirts, workwear, aprons, towels, bathrobes. On very thin or elastic t-shirts embroidery is not ideal.

When is embroidery worthwhile?

Embroidery is the right choice as soon as quality, durability and industrial suitability count. Specifically:

• Fabrics — polos, caps, fleece, sweat fabrics, workwear, aprons, bathrobes. Embroidered logos on dense fabrics look refined and survive every wash.
• Designs — company logos, club logos, emblems, lettering, crests. Photo motifs are not possible because embroidery works with discrete thread palettes.
• Quantities — typically from 10-25 pieces (so the digitisation pays off). Single items are technically possible but cost more per unit.
• Applications — staff polos in companies, hotel aprons, safety workwear (B&C Pro, Mascot), hospitality outfits, cap promotions, club polos.

If your motif contains a photo or the textile is a thin t-shirt, screen print, DTF or digital print is the better choice.

Benefits and limits of embroidery

Benefits:

• Refined look — tactile, optically dimensional, premium feel.
• Maximum durability — 100+ industrial washes without visible wear, boil-proof.
• Universal on dense fabrics — works on every polo, fleece, cap, workwear fabric.
• Reusability — we keep your embroidery file on file; reorders with the same logo are quicker to set up and come out identical.
• Brand standard for workwear and hospitality.

Limits:

• No photo motifs — embroidery works with threads, not pixels.
• Not on thin t-shirts — thread distorts thin fabric, the result "sags".
• Digitisation cost — €27.50-88 net per logo and size, on every order (depending on embroidery area, see price table).
• Higher unit price than print methods at large runs.
• Smallest font height around 4-5 mm — finer text blurs.

Minimum order and prices

Embroidery is possible from 1 piece; it typically pays off from 10-25 pieces. Unit prices depend on the embroidery area (in cm²) and the quantity. Digitisation is charged per design and size on every order, including reorders; we keep your embroidery file on file.

Unit price (€ net per piece) and digitisation fee

All prices net, plus VAT, per embroidery position, excluding the garment. The columns apply to 20–49, 50–99, 100–149 and 150–199 pieces. The price ladder already starts at 1 piece and continues to 500+ pieces — overall from €34.99 (up to 250 cm², 1–9 pieces) down to €2.04 (up to 5 cm², 500+ pieces); the configurator applies the right tier automatically. From 250 cm² embroidery area: price on request.

Size guide

Complex emblems or special threads (metallic, 3D, multicolour) — please specify via the enquiry form, we calculate individually.

Examples from our production

A selection of typical orders:

• Tax consultancy company polos — 32 polos Russell Performance Polo, 8×8 cm chest logo two-colour (64 cm² ≈ table row up to 70). Embroidery €9.12 net per piece (20–49 pieces), digitisation €44 net for this order.
• Hotel aprons — 24 aprons with large hotel logo, embroidery file reused for bathrobes.
• Club polos — 18 polos with club crest plus individual first name per player — the crest digitised once for the order, first names embroidered individually per piece.
• Workwear craft business — 15 softshell jackets with elaborate 3-colour logo, combined with embroidered first name.

More use cases under business clients trades and hospitality.

How ShirtStore works

1. Choose your product — polo, cap, fleece, workwear or hoodie. Embroidery-suitable models are flagged in the configurator.
2. Upload your logo — vector (SVG, PDF, AI, EPS) ideal. Pixel from 600 dpi at final size is possible. More on file requirements.
3. Digitisation and mock-up — we digitise your logo and send an embroidery mock-up (preview plus estimated stitch count) for approval.
4. Production — typically 8-12 working days because digitisation and embroidery machine capacity must be considered.

Embroidery applications — what works best where?

Embroidery vs. print decision matrix

Configurator workflow — embroidery order in 5 steps

1. Pick the article. Premium polos (B&C Pro Heavy, Stedman Lux, Stanley/Stella Performer), workwear, caps, hoodies and bags are ideal for embroidery.
2. Upload the logo. Vector SVG/PDF preferred. For pixel logos: at least 600 dpi at final size. Logo size 5–8 cm wide is standard for chest embroidery.
3. Digitisation check. Our digitisation team converts your vector to a stitch file (digitisation €27.50–88.00 net by embroidery area, charged per order). Existing DST/EMB files: we check them and can use them directly.
4. Choose thread colours. Standard polyester thread in approximately 250 colours. Pantone-true matching available on request and included in the price (specify Pantone reference).
5. Approve the preview. Digital mock-up plus optional fully embroidered sample piece (price on request) before bulk production.

Example scenarios — three typical embroidery orders

Case 1 — Lübeck hotel chain, 125 Lux polos with logo embroidery

A hotel chain orders 75 Lux Polo Men + 50 Lux Polo Women in brand colour sand. Finishing: embroidery left chest (hotel logo, 7 cm, Pantone gold thread). Embroidery priced by area and quantity per the table above, plus digitisation for this order. Pantone matching is included in the price; an embroidered sample is optional (price on request).

Case 2 — Munich construction company, 85 B&C Pro tees with logo embroidery

A construction company orders 85 B&C Pro tees (TUC01) in hi-vis orange for the outdoor crew. Finishing: embroidery left chest (logo three-colour, 8 cm) + back (company lettering, embroidered). Requirement: suitable for industrial washing at 60 °C.

Case 3 — Berlin IT consultancy, 35 Flexfit caps with embroidered logo

An IT consultancy with 35 staff orders 35 Flexfit 6277 in heather grey for a conference. Finishing: embroidery centre front (company logo, single-colour, Pantone match). Lead time: embroidery 8–12 working days production plus shipping.

What our embroidery service includes

• Transparent digitisation fee — net by embroidery area, from €27.50 (up to 20 cm²) to €88.00 (up to 250 cm²), charged per order.
• Pantone-true thread matching — on request we match standard polyester thread to the exact Pantone reference of your brand; this is included in the price.
• Embroidered sample option — fully embroidered sample piece on request (price on request). Important for hotel and luxury brand orders where the exact thread tone matters.
• Stitch file kept on file — clubs and businesses with annual orders get the same stitch file reused, so reorders come out identical. Digitisation is charged on every order, including reorders.

Ready for your embroidery?

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ShirtStore is your partner for machine embroidery in Germany and Europe. We embroider polos, caps, fleece jackets, aprons, workwear, softshells, sweatshirts, bathrobes and towels with company logos, club crests, emblems and lettering — tactilely refined, optically high-end and with 100+ washes durability boil-proof. Our in-house digitisation studio creates a professional embroidery file from your logo, which we realise on modern industrial embroidery machines with multiple heads. Standard thread is Madeira or Gunold polyester in over 250 colours, Pantone matching on request. Volume discount on the garments applies from 3 pieces (3 % → 10 % → 15 % → 25 % → 30 % → 32 % at 3/20/50/100/200/500); embroidery and digitisation are excluded. Typical applications are staff polos in companies, hotel aprons and bathrobes, workwear in trades and industry, club caps and promo caps. Compared with print methods, embroidery brings a digitisation fee per order (€27.50-88 net depending on embroidery area); we keep the embroidery file on file for reorders. Compared with DTF print or digital print, embroidery is more durable and refined but not suitable for photo motifs. For logos on dense fabrics, embroidery is the gold standard. ShirtStore.de — embroidery with craftsmanship precision.

Further Reading

• Embroidery — Wikipedia — history, techniques and applications
• Madeira — leading manufacturer of premium embroidery threads
• Tajima — manufacturer of industrial multi-head embroidery machines