If you are looking for custom football kits or custom scarves, understanding how they are actually produced makes a real difference.
Last month, it was that time again. We visited some of our production facilities in Portugal. For me, it was the first time, and I can already say that it was definitely a highlight.
In this post, I’ll share why we take these trips, what impressed me most, and what really goes on behind the scenes of our custom sports merchandise.
Why We Travel to Portugal
As a team at Hercules Merchandise, we travel to Portugal once a year to visit our production partners in person.
Of course, it is about staying in touch. More importantly, it is about building trust. When you are working with custom sports merchandise, tight deadlines and individual designs are part of everyday business. This only works if the collaboration runs smoothly.
That is why it is important for us not to rely only on emails or calls, but to meet face to face. Being on site gives you a completely different perspective.
It also allows us to maintain consistent quality and a reliable production process for every order.
First Impressions: More Real Than Expected
We visited three different production facilities, mainly focused on custom scarves and custom sportswear.
I already had a general idea of how things worked, but seeing it in real life is something else entirely.
The facilities varied in size. Some were quieter, others were quite loud, with machines running at full speed. All of them were clean, well organised, and highly structured.
What stood out most to me were the people. I had only known many of them through emails before, so meeting them in person and experiencing the open, welcoming atmosphere was a real highlight.
You can tell immediately when a team works well together.
How Our Products Are Made Behind the Scenes
What surprised me the most was how many steps go into a single product.
Custom Scarves
Step 1: Design
Everything starts with a digital design file. This file is converted into a machine readable format and adjusted based on technical factors such as stitch density and colour limitations.
This creates a precise blueprint that defines every single stitch.
One thing I learned quickly at Hercules Merchandise is that a good design is not only about appearance. It also has to work technically.
Step 2: Production
Depending on the style and level of detail you need, you can choose between several types of custom scarves:
- Woven scarves are produced thread by thread, with the design integrated directly into the fabric.
- Jacquard scarves are knitted using multiple yarn colours combined stitch by stitch to create the design.
- HD Deluxe scarves, also known as spandex scarves, use finer yarns and tighter knitting, allowing for more detailed and complex designs.
- Printed scarves are created using heat and pressure, which allows for detailed graphics and colour gradients.
This variety allows clubs to choose the best option depending on their budget, design complexity, and how the scarves will be used.
Step 3: Finishing
Finally, the scarves are sewn together, fringes and labels are added, and everything is ironed and quality checked before being prepared for shipping.
This is where attention to detail really matters.
Custom Sportswear: Sublimation
For custom sportswear, such as custom football kits, we use sublimation.
This means the design is embedded directly into the polyester fibres instead of being applied on top of the fabric.
The result is a smooth finish with no added layer.
The main advantages are:
- no feeling of print on the surface
- long lasting durability
- vibrant, high quality colours
It also offers complete creative freedom, from colours and patterns to styles such as crew neck, V neck, or polo collar.
After printing, the fabrics are cut, sewn together, optionally finished with custom labels, and prepared for delivery.
What Impressed Me Most
What really stood out to me was the attention to detail.
Nothing is rushed. Colours, materials, and designs are carefully checked and adjusted when needed before production is finalised.
Behind it all are people with years of experience who clearly take pride in what they do.
It made me realise that there is not just machinery behind these products, but real craftsmanship.
Why This Matters for You
These visits are not only interesting for us. They are essential for you as a customer.
In the end, it is about:
- consistent quality
- reliable delivery
- accurate execution of your designs
Working closely with our production partners also allows us to be more efficient. This helps us keep our prices competitive while maintaining a high level of quality.
Knowing who we work with and how they operate makes a real difference when delivering custom sports merchandise.
Final Thoughts
This trip to Portugal gave me a completely new perspective.
Seeing how an idea turns step by step into a finished product, and how many people are involved, was incredibly insightful.
More than anything, it showed me how important strong partnerships are. Behind every product, there is not just production, but trust.
I am already looking forward to the next visit.
Ready to create your own custom products?
Explore our custom football kits or get in touch to start your project with a free design.
Author
Article written by Lea
Project Manager for UK at Hercules Merchandise
