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color-matches the provided artwork to the
customer’s specified PMS color, ensuring the
best possible match.
A sample is printed, then it is pressed
(dye sublimated). In-house color experts use
the most advanced color-analyzing tools to
ensure that the CMYK color on the finished
product is the optimal match to the cus-
tomer-specified PMS color. Once the product
has passed this color quality-control point,
the printing begins.
While the full-color digital print is made,
the microfiber is moved to the preparation
area and is cut to the specified size. To ensure
quality and consistency of the shape, the
optimal number of microfiber layers are cut
simultaneously.
Once the printing is completed, the proj-
ect moves to the pressing stage. After con-
ducting the necessary tests, a dye-sublimation
technician sets up the printed reel of paper
on the press and carefully aligns the pre-cut
pieces of microfiber to the printed artwork.
The cut pieces move to a master sewer,
who sews the Wedge almost to completion.
The Wedge is then filled and finished with
the final stitching up the back.
APRIL 2015 •
PPB
• 93
Toddy Gear’s sublimation technician care-
fully aligns the pre-cut pieces of microfiber
to the printed artwork.
The Wedge™ fabric is color matched and
digitally printed.
The material is fed through the press and
the pre-cut pieces are manually removed
from the press as they are finished.
A master sewer stitches the fabric (above)
before it is sent to be filled (below) and
finished with the final stitches.
ABOUT TODDY GEAR
Founding date
2011
Principal
Todd Gabel, President
Size of production facility
50,000 square feet
Types of specialized equip-
ment
Toddy Gear has six types
of specialized equipment for
printing, dye sublimation, cut-
ting and sewing.
Notable accomplishments
This
year the supplier introduced the
Smart Pouch Zip, a dual-sided
microfiber pouch decorated
with full color-full bleed. The
supplier also entered the UV
printing arena in promotional
products the same month, intro-
ducing a UV-printed full-color,
full-wrap power bank.
A print production technician prepares The
Wedge™ for print.