Quick answer: Merch minimums exist because decoration has setup costs (screens, embroidery files, press time), so suppliers need enough pieces to make the price per item reasonable. Sizes and colors multiply the risk: a 48-piece hoodie minimum spread across five sizes and two colors can leave you with boxes of slow sizes. Start with size-free items (mugs, totes, stickers), order apparel for two to three months of sales in your top sizes, and reorder winners instead of guessing big.
Key takeaways
- Minimums cover setup costs; bigger runs mean lower per-piece prices.
- Sizes and colors multiply risk.
- Size-free merch is the safest place to start.
- Reorder winners rather than overbuying up front.
Why minimums exist
Every decorated item starts with fixed setup work: preparing artwork, burning screens for screen printing, digitizing logos for embroidery, setting up presses and test prints. Those costs barely change between 24 and 240 pieces. Spread across a small run, they make each item expensive; across a larger run, they nearly disappear. That's why suppliers set minimums and price breaks.
How sizes and colors multiply the problem
A minimum is usually per design and sometimes per color. Apparel adds a size curve on top.
Illustrative 48-hoodie order in one color:
| Size | Typical share | Pieces | Risk |
|---|---|---|---|
| S | 10% | 5 | Slow |
| M | 28% | 13 | Sells |
| L | 30% | 15 | Sells |
| XL | 20% | 10 | Moderate |
| 2XL | 12% | 5 | Slow |
Add a second color and you've doubled every row. Add a youth size and a 3XL and you've created several more slow-moving SKUs. The order meets the minimum, but your cash and closet carry the leftovers.
Start with size-free merch
Items without sizes are simpler to forecast and display:
- Mugs and tumblers: see our custom mugs guide and tumblers guide
- Tote bags: see our tote bag guide
- Stickers and pins: low cost, high margin, easy add-ons
- Caps and beanies: one-size or limited sizes
Once these sell steadily, you'll have the data and confidence to add apparel.
A simple ordering method
- Estimate monthly sales. If you're new to merch, assume a modest number, such as one item per 200–300 transactions, then adjust after a month.
- Pick a supply window. Two to three months is a good first order.
- Apply a size curve weighted to M and L for adult apparel.
- Choose one color (two at most) for the first run.
- Compare to the minimum. If the minimum is far above your estimate, choose a lower-minimum decoration method or a size-free item instead.
- Plan the reorder before you sell out: note the lead time and the stock level that triggers a reorder.
Ways to lower risk
- Lower-minimum decoration methods: direct-to-garment printing and some heat transfer methods allow small runs, at a higher price per piece.
- Pre-orders: take pre-orders for hoodies in each size, then order exactly what's sold plus a small buffer.
- Limited drops: announce a numbered or seasonal run; scarcity helps it sell through.
- Staff uniforms first: a run that doubles as team apparel uses up odd sizes.
- Bundle slow sizes with drink cards or beans to move them.
Price for the leftovers
Assume some pieces won't sell at full price. If you expect 10% to end up as staff gifts or discounted items, build that into your price. See our merch pricing guide.
Track sell-through
| Metric | Formula | Healthy sign |
|---|---|---|
| Sell-through | Units sold ÷ units received | 60%+ in the first two months |
| Weeks of supply | Units on hand ÷ weekly sales | Under 12 weeks |
| Size balance | Sales by size vs. order by size | Reorder to match real demand |
Display tips in our café retail display guide help merch move faster.
When a big order makes sense
Larger runs are worth it when you have proven demand, a reliable reorder pattern, multiple locations or events where merch sells in volume. Even then, keep sizes balanced and stagger deliveries if your supplier offers it.
Order merch that matches your volume
Affogato Bean quotes branded apparel, mugs, totes and accessories at multiple quantities, with design help included, so you can choose a first run you'll actually sell. See products or talk to us.
Frequently asked questions
Why does custom merch have minimum orders?
Decorating merch involves setup work such as screens, embroidery files or press setup. Minimums spread those fixed costs over enough pieces to keep the price per item reasonable.
How many hoodies or T-shirts should a café order first?
Order what you expect to sell in two to three months, weighted toward the most common sizes (usually M and L), in one or two colors. It's better to reorder a sellout than store leftovers.
What merch has the lowest risk for cafés?
Items without sizes, such as mugs, tote bags, stickers and tumblers, are lower risk because you don't have to guess a size curve.