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HOW TO PLAN A CUSTOM APPAREL ORDER FOR SEASONAL EMPLOYEES RETURNING IN THE FALL

September 10th, 2026 • 5 minute read

Table of Contents

Introduction

Many businesses hire seasonal employees who return each fall. Planning a custom apparel order for these part-time teams requires thoughtful consideration to meet varying needs while maximizing budget and timing. Whether you’re outfitting a retail staff, hospitality workers, or event personnel, this guide will help you confidently navigate the process.

Understanding the Needs of Seasonal Employees

Seasonal employees often work during transitional weather periods, so the apparel you choose should accommodate changing temperatures. Additionally, these employees may vary in size, role, and shift duration, making flexibility key.

  • Employee Count and Turnover: Determine the number of returning employees and plan for fluctuations.
  • Work Environment: Evaluate indoor vs. outdoor roles and weather exposure.
  • Required Apparel Types: Identify if you need just shirts or also layers like sweatshirts, jackets, or hats.
  • Branding Needs: Align apparel with your company branding for consistency.

Choosing the Right Types of Custom Apparel

Since fall weather can be unpredictable, layering options often work best. Consider offering a mix of:

At Underground Printing, we offer a wide range of apparel options suitable for fall seasonal employees, from soft tees to branded outerwear.

Considerations for Apparel Quality and Comfort

Your seasonal employees need comfortable, durable apparel that fits well. Choosing quality materials and popular brands can enhance employee satisfaction.

  • Look for moisture-wicking and breathable fabrics like dri-fit t-shirts to keep employees comfortable during active work.
  • Soft cotton options provide everyday comfort, such as those found in our soft t-shirts collection.
  • Consider durable outerwear brands such as The North Face, Columbia, or Patagonia for lasting jackets.

Planning Your Order Size and Inventory

Since seasonal workers return each fall, it's important to plan your order quantities and stock effectively:

  • Review previous years’ data to estimate how many employees will return and what sizes were most common.
  • Consider ordering some extra apparel to accommodate unexpected hires or size exchanges.
  • Leverage bulk ordering to get better pricing and ensure availability.
  • Plan shipments and inventory storage to distribute apparel before the season starts.

Design and Branding Tips for Seasonal Apparel

Consistent, professional branding on your apparel helps build team spirit and promotes your company. Here’s how to approach custom designs:

  • Keep designs simple and clear for quick recognition.
  • Use quality screen printing for vibrant colors that last through repeated wear.
  • Consider embroidery for logos on hats, jackets, or polos for an upscale look.
  • For detailed or photo-quality images, explore direct-to-garment printing.
  • Include your website or social media handles discreetly to promote your brand beyond the workplace.

Managing Ordering Timelines for Seasonal Staff

Timing is essential to ensure your team has their apparel when they need it.

  • Start the ordering process well in advance—ideally 6 to 8 weeks before employees return in the fall.
  • Account for order production times and possible rush periods; Underground Printing offers a 2-day rush option for tight deadlines.
  • Use tools such as a pop-up online store for easy team member ordering and size selection.
  • Coordinate with your account representative to set milestones and confirm samples or proofs early.

FAQs About Seasonal Custom Apparel Orders

How can I handle sizing changes for returning seasonal workers?

A pop-up online store or pre-season survey can help employees select sizes ahead of time. Also, ordering a small overage in popular sizes helps manage last-minute changes.

What are the benefits of choosing custom sweatshirts or jackets for fall?

They provide warmth, promote your brand, and increase professional appearance. Durable fabrics and quality branding ensure the apparel lasts multiple seasons.

Can I mix different apparel types in one order?

Yes, combining items like t-shirts, sweatshirts, and hats in your order helps meet diverse employee needs and allows layering for comfort.

What printing methods work best for fall apparel?

Screen printing is great for bold logos on shirts; embroidery adds texture and permanence on outerwear and hats; DTG works well for complex or colorful designs.

How can I get started with ordering?

You can get started with a quote or consultation at Underground Printing to explore options tailored to your business needs.

Conclusion

Planning a custom apparel order for seasonal employees returning in the fall involves anticipating needs, choosing suitable apparel types, and managing order timing carefully. By selecting quality clothing and thoughtful designs from Underground Printing, you can ensure your team looks unified and feels comfortable all season long.

Ready to outfit your seasonal team? Contact us today to discuss your custom apparel needs and start your order with confidence.

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