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Case Studies

Second Time Around

How learning from experience improves production



KDM P.O.P Solutions Group (, a Cincinnati-based p-o-p graphics solutions fabricator, was recently tapped to produce 567 quarterly banners for Fifth Third Bank. The project had a 10-day firm deadline and consisted of three banner versions that would vary by the demographics of the location in which they would be displayed. Versions were divided into 482 copies, 60 copies, and 25 copies.

“This was the second time we have produced the bank’s quarterly banners,” recalls Dan Kimmerly, graphics director at KDM. “The first time, it did not go so smoothly—we had some slurring or ghosting on the printed banners, and the cutting was a real challenge.

“This time,” Kimmerly continues, “we put several measures in place, such as first nailing down the bank’s corporate logo colors, pre-shrinking the fabric, and creating a template for cutting as well as a better process for keeping track of every piece during production—printing, heat transfer, cutting, and sewing. We are very pleased with how smoothly the project went and how great it looks this time around.”

KDM used Adobe Photoshop and Illustrator to create the image files and its new 54-inch Roland XJ540 printer with Wasatch SoftRIP to reverse print the images onto transfer paper with Sawgrass Sublime dye-sublimation inks. Total printing time was five days. The company then heat-transferred the images to Fisher Textiles’ Poly Poplin fabric using a Praxtix OK-12 heat press.

Using a hand-held heat knife, KDM staff made the edges clean and ensured they would not fray. The company created a new template because the banners were tapered at the bottom, not square. Final finishing consisted of creating pole pockets at the top and bottom. The finished graphics measured 19 x 17 inches and were 71-inches tall.

“We learned so much on this project. It was great to see all the measures we put in place pay off. We will be able to apply these to future dye-sub long runs,” Kimmerly adds.




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