The inter-house brief from Tongaat
The client was a local school in Tongaat preparing for inter-house week, where each house needed its own shirt colour and a clear printed identity for learners, staff and supporters. The brief was simple in one sense and tricky in another: the shirts had to look consistent across sizes, the print had to stay bold after washing, and the finished garments had to reach the school before the events started.
Because house shirts are worn in class, on the field and at assembly, the school wanted a print that would stand up to heat, sweat and repeated use. The order also had to be practical for storage and handing out, with each house separated and counted so nothing got mixed up. For school work, that organisation matters just as much as the printing itself.
- Client type: school in Tongaat
- Project: inter-house shirts for a school competition week
- Print use: daily wear, sports and prize days
- Key need: clear house identification with durable print
Artwork checks and colour separation
The artwork arrived with the main house elements, and we checked it for line thickness, spacing and print suitability before production. School garments can be unforgiving if the artwork is too fine or if the contrast is weak, so we redrew parts of the design into cleaner vector artwork and separated the colours for screen work. That step helps keep every shirt looking the same, even when a run includes many sizes and multiple house colours.
Our production team then prepared the films and screens in-house. We handled the artwork checking, vector redrawing, colour separation and film output on site, which kept the job moving without waiting on outside suppliers. For a school project on a deadline, that kind of control is important because if one step slips it can hold up the whole order.
- Artwork checking for screen suitability
- Vector redrawing for clean edges and consistent sizing
- Colour separation for each print layer
- Film output prepared for screen exposure
We also made sure the logo and house text would sit correctly on the shirt front. A print that is too high, too low or slightly off centre shows immediately on a school garment, so registration was checked before the main run started. It sounds basic, but it saves a lot of hassle later.
Screen making, exposure and production setup
Screen Spectrum handled the full screen making process in-house, from stencil prep through to exposure and washout. The screens were stretched, coated with emulsion, exposed and then washed out and touched up where needed. That gave us clean screen edges and a solid base for the print run, which is what you want when a job has several house colours and a fixed delivery date.
Once the screens were ready, we ran a test print on the chosen shirts to confirm colour strength and placement. This is especially useful on schoolwear because different garment colours can affect how the print reads. A pale shirt behaves differently from a darker one, and if the school wants one house to stand out more than another, we can make the adjustment before full production.
- Screen stretching and reclaiming done in house
- Emulsion coating and screen exposure prepared for a clean stencil
- Washout and touch-up for sharp detail
- Test printing before the full run
We kept the screens stored and labelled for the duration of the job so any reprint or extra piece could be matched later if needed. For schools, that matters because the year group counts can change at short notice and a few extra shirts are often needed after the first handout.
Handling mixed sizes and school-week timing
The order was completed over a two week production window, which gave enough time for pre-press, printing and dispatch without rushing the finishing stage. The school had a set date for inter-house week, so the timing had to work backwards from that point. That is usually how school clothing jobs go in Durban and surrounds, especially when the garments are needed for a specific event rather than general stock.
We sorted the shirts by size and house before packing, and that kept the distribution side simple. For a school in Tongaat, there is also the practical matter of transport timing and weather. Coastal humidity can affect handling and packing, so the garments were allowed proper drying and then packed neatly to avoid sticking, creasing or print scuffing.
- Production timeline: 2 weeks
- Sorted by size and house before dispatch
- Packed for clean handover and easy distribution
- Prepared for school event timing, not retail shelf stock
The result was a job that moved from artwork approval to final packout without drama. There was no need for repeated back-and-forth, which kept the school team focused on the event itself rather than chasing printing updates.
What the finished shirts needed to achieve
The finished shirts had to do more than look good on day one. They needed to make each house easy to identify across the field, in the classroom and in group photos. A house shirt has a job to do all week, and in many schools it becomes a keepsake after the event is over. If the print cracks, fades or feels heavy, the shirt ends up at the back of a cupboard. So the finish had to be neat, comfortable and hard wearing.
For this project we focused on print clarity, repeatability and a balanced hand feel. The aim was to keep the design visible without making the garment stiff. That matters for children and teenagers because they are moving all day, and a print that feels too thick can be uncomfortable in Durban heat. We used a production method suited to repeat schoolwear rather than one-off novelty items.
- Clear house identity from a distance
- Print finish suitable for repeated washing
- Comfortable enough for all-day wear
- Consistent look across the full size run
The school received shirts that looked organised and ready for issue. That sort of presentation matters when the staff are handing out items to several houses at once. A tidy finish reflects well on the event itself and makes the whole week feel properly planned.
Delivery, results and what we would repeat
Once the shirts were completed, they were prepared for collection and delivery handling through our Durban base, with courier support available for the wider KZN route and beyond. For this Tongaat project, the main result was simple: the school had finished house shirts on time, with the print quality and sorting handled in a way that made distribution straightforward. No last-minute scrambling, no mixed bundles, and no unclear sizing issues.
If we were repeating this type of project again, we would keep the same approach: confirm the house artwork early, separate the colours properly, run a test print, and pack each house separately at the end. That method works for schools because it reduces the chance of error and makes the final handover much easier. It also leaves room for a small top-up run if one house needs extra pieces before inter-house week starts, which happens more often than people think.
- On-time completion for the school event
- Neat distribution by house and size
- Durable print suited to active school use
- Simple re-order path if extra shirts are needed
For school projects in Tongaat, Durban and the wider KZN area, we find that a practical process works best. Good screen prep, checked artwork and clear packing are what keep the job moving, even when the deadline is tight.
Key facts
| Client type | School in Tongaat |
|---|---|
| Project | House competition shirts for inter-house week |
| Production time | 2 weeks |
| Printing method | Screen printing with in-house screen making |
| Artwork work | Checking, vector redrawing and colour separation |
| Delivery area | Tongaat with courier delivery across South Africa |
