Expansion, Revision, and Investments with TC Screen Printing

TC Screen Printing is based in Siloam Springs, Arkansas, but its path also includes California. Founded over a decade ago, the business has evolved and honed its focus on providing retail experiences, particularly in the cycling industry. 

Like many people, Owner Tyler Carroll’s journey in the print world started in the industry, working in a screen printing shop. He began learning the ropes while at that business, but Tyler says he became dissatisfied and decided to make a significant life change over time.

“The day after I quit my previous job, I decided to start my own screen printing business,” he says. This shift was 14 years ago, and began an exciting entrepreneurial journey.

Moving Between States 

Tyler moved to California from Arkansas and ran his business for the first four years there. After several years in California, they noticed a high demand for services in Arkansas, Tyler’s home state.

“We were shipping many products back to Arkansas, highlighting a gap in the local market,” he states. 

Recognizing this opportunity, TC opened a location in Arkansas and eventually moved back full-time after selling their California operations to a friend.

Expanding Operations 

Returning to Arkansas proved to be a strategically wise move, as the business has continued to grow and build a reputation as a go-to printer in the greater Bentonville area over the past few years. 

TC Screen Printing recently moved into a new facility, an expansive 57,000-square-foot building. Initially, the business planned to build a new 20,000-square-foot facility, but skyrocketing construction costs made that goal difficult. Instead, they purchased an existing building just a quarter mile from their old location.

The new property spans seven acres and includes an additional 10,000-square-foot outbuilding. Tyler says the outbuilding is in rough shape, but the main facility provides ample space for the business’s growing operations.

“In the next two months, we’ll be operating out of 30,000 square feet from that 57,000,” he adds.  “And we’re expanding our warehouse and e-commerce capabilities.” 

Buying vs. Leasing 

Tyler’s decision to buy rather than lease was driven by cost efficiency. The building was incredibly affordable, and leasing a comparable space would have cost three to four times more. Additionally, they’ve monetized the excess space by offering commercial storage.

“We’ve split the back 25,000 square feet into commercial storage units that we lease out, effectively covering the building’s mortgage,” he adds. 

Having been involved in commercial real estate since relocating back to Arkansas, Tyler says the business was also able to dial in its strategy for moving into its current space. It’d previously owned and successfully managed several buildings, purchasing properties that had since quadrupled or quintupled in value. The business’s latest acquisition was one of three nearly abandoned warehouses in Siloam Springs.

“Although our operations are based in rural Arkansas, we’re strategically located near the University of Arkansas and Walmart’s headquarters in Bentonville,” Tyler says. “This proximity means that while real estate in our immediate area is affordable, nearby commercial property markets are highly competitive with low vacancy rates.”

Maintaining Multiple Sites

Now entirely situated in Arkansas, TC Screen Printing has an office near Walmart’s headquarters in Bentonville and its main headquarters. The Bentonville office is a small retail storefront and project management hub strategically located in the downtown arts and business district. This proximity to their customers allows for easier customer visits, many of whom ride their bikes to the office thanks to the area’s bike-friendly infrastructure.

TC staffs its Bentonville office with a full-time project manager and support from hybrid employees who split their time between this office and company headquarters. One of their artists works there two days a week to meet clients’ needs. This setup allows them to maintain a high level of service without requiring clients to travel far, enhancing their experience and convenience.

Tapping into the Heat-Applied Graphics Market

While screen printing is still at the core of what TC Screen Printing prides itself on, the business has also spent recent years exploring and tapping into the profitability of heat-applied graphics, including direct-to-film (DTF). Initially, Tyler says heat-applied graphics were limited, handling only a few weekly jobs with in-house vinyl cutting or printable vinyl. 

However, the demand has skyrocketed, and they now operate about 8-9 double-sided heat presses daily, covering a variety of applications from tags and sleeves to hats. Regarding volume,  jobs can range from 15-20-piece orders to larger 250-piece runs for customers like a recent rodeo event. 

Given the increasing volume and variety of DTF jobs, Tyler says the business is considering purchasing a DTF printer since it’s been able to expand the kinds of colors and artwork TC Screen Printing can offer customers without affecting efficiency and quality. 

E-commerce and Team Stores

In addition to high-quality printing, TC Screen Printing has been using e-commerce to grow its business and tap into more customers. With Printavo Merch, they manage various team stores and are preparing for a significant expansion in this area.

“We’re targeting 500 cycling teams in a youth program called NICA (National Interscholastic Cycling Association), offering them customized team stores,” Tyler says. 

He says the organization’s philosophy, “more kids on bikes,” resonated deeply with him as an avid cyclist and his children’s interest in cycling.  

Initially, TC Screen Printing supplied merchandise for NICA’s events but noticed they weren’t maximizing their revenue potential and compromising quality to meet specific price points. To address this, Tyler pitched a new idea: create a collegiate-level store on-site at their races.

“One league took a risk and said yes, and four years later, we’re now present in 19 states across the country,” he adds. 

Down the Road 

Looking forward, Tyler and his team are excited about the potential new applications of DTF technology. For instance, they are exploring how high-color, eye-catching designs can drive sales in the cycling industry. The ability to quickly produce and restock these designs can significantly impact their merchandising programs.

Additionally, Tyler sees potential in on-site printing at events, adding a wow factor for customers. This approach could enhance the retail experience, providing a unique selling point and increasing customer engagement. While they are still in the experimental phase, the idea is to balance the immediacy of on-site printing with the efficiency of pre-made products.

From selling a shop to expanding into a new facility, TC Screen Printing’s journey has been filled with learning experiences and strategic decisions. They’ve navigated the complexities of business deals and continued to grow and speed up delivery times with technologies like DTF printing.