Bulk Orders vs Small Batches – Which Merch Kit Order Size Actually Works for You?

Choosing the Right Order Size for Your Business Needs

Bulk order vs. Small Batch: Which is right for you?

• Bulk Orders - Best for orders of 100+ units, offering lower cost per unit (15-30% savings), longer lead times (2-4 weeks), and ideal for standardised items
• Small Batches - Best for orders under 100 units, higher cost per unit but lower upfront investment, quicker turnaround (1-2 weeks), and greater flexibility

Making a bulk order decision doesn't have to be complicated. Whether you're looking to outfit your entire team with branded merchandise or testing the waters with a small promotional run, understanding which order size works best for your specific needs can save you time, money, and storage headaches.

The right choice depends on several factors: your budget constraints, timeline requirements, storage capacity, and how you plan to use the merchandise. Small batches offer flexibility and lower upfront costs, while bulk orders provide significant per-unit savings and consistency across your branded items.

Many businesses struggle with this decision because they're trying to balance immediate needs with long-term value. The good news? You don't have to choose blindly.

I'm Ben Read, co-founder of Mercha.com.au, and I've helped thousands of businesses steer bulk order decisions to find the perfect balance between cost efficiency and practical merchandise solutions.

Small Batch Orders: Flexibility and Agility for Your Brand

There's something wonderfully nimble about small batch merchandise orders. Like a boutique café that crafts just enough pastries for the day's customers, small batch merch (typically under 100 units) gives your brand room to breathe, experiment, and evolve.

Small batches shine brightest when you're running a startup or small team where every dollar counts. They're perfect for those moments when you want to dip your toes in the promotional merchandise waters without diving headfirst into a sea of inventory. Many of our clients at Mercha begin their journey with us this way – testing the waters before making bigger commitments.

These smaller orders are also brilliant for pilot programmes where you're testing concepts before a wider rollout. Imagine creating just 25 branded notebooks for your sales team to see if they actually use them before ordering 250 for the entire company. That's smart business.

For limited edition campaigns or seasonal promotions, small batches ensure you're not left with boxes of "Summer Splash 2024" tote bags when autumn rolls around. And when it comes to personalisation, smaller runs give you the freedom to create something truly special – like custom team kits with individual names or department-specific branding.

Industry data backs this approach too – businesses that test with small batches before scaling up report 40% higher satisfaction with their final merchandise selections. It's like sampling a few flavours before committing to a whole tub of ice cream.

Want to make your small batch ordering even smoother? Our guide on 7 Time-Saving Tips to Use When Ordering Merch has you covered with practical advice from our team of merchandise experts.

Pros of Small Batch Orders

The beauty of small batch orders lies in their flexibility and lower barriers to entry. With a lower upfront cost, you can explore branded merchandise without breaking the bank or seeking special budget approval. This makes it ideal for teams working with tight quarterly budgets or wanting to test waters before diving deeper.

Small batches also give you the freedom to try different styles – perhaps ordering 20 each of three different t-shirt designs to see which your team prefers. This real-world testing is invaluable; no amount of mockups can tell you how a product actually feels in hand or wears after a few washes.

When time is of the essence, small batches deliver with faster turnaround times. While a bulk order might take 2-4 weeks to fulfil, smaller runs can often be in your hands within 1-2 weeks.

There's also significantly less risk involved if your priorities shift. In today's fast-moving business environment, brand refreshes and campaign pivots happen regularly. With small batches, you won't be stuck with hundreds of items sporting outdated logos or messaging.

Finally, the quality control advantage can't be overstated. With a smaller run, you can thoroughly check each item and address any issues before committing to larger quantities. It's the difference between finding a printing issue on 25 items versus 500.

Cons of Small Batch Orders Compared to Bulk Orders

While small batches offer wonderful flexibility, they do come with trade-offs worth considering. The most notable is the higher cost per unit. Without the economies of scale that come with larger orders, you might pay 15-30% more per item. That branded water bottle might cost $15 each when ordering 50, but drop to $10 each in quantities of 250+.

You'll also be missing out on bulk discounts that kick in at higher quantities. These tiered pricing structures can make a significant difference to your marketing budget over time.

Another consideration is that limited quantities may not meet unexpected demand. If your branded caps become the surprise hit of your product launch, you might find yourself scrambling to reorder while momentum is high.

For businesses with tight deadlines needing promotional products quickly, we've compiled a handy guide: Need It Fast? Best Rush Promo Products for Quick Branding. This resource highlights which items can be produced most quickly when time is of the essence.

Small batch ordering isn't inherently better or worse than bulk ordering – it's simply a different approach for different circumstances. The best choice depends on your specific needs, timeline, budget, and how you plan to use your branded merchandise. And remember, many of our most successful clients started small and scaled up as they refined their merchandise strategy.

Bulk Orders: Maximising Savings and Consistency

There's something quite satisfying about placing a bulk order for branded merchandise. When you're planning for quantities of 100+ units, you're not just buying products – you're making a strategic investment in your brand's presence. The economies of scale open up a world of benefits that can transform how you approach your merchandising strategy.

Think about it – instead of scrambling to place last-minute orders throughout the year, you could have a well-organised, cost-effective approach that keeps your brand consistently represented. This approach works brilliantly for businesses with predictable merchandise needs.

Bulk orders shine particularly bright for several common scenarios. If you're planning a major product launch or conference where hundreds of attendees will receive your branded items, bulk ordering ensures everyone gets the same high-quality merchandise while you enjoy significant cost savings. For companies that regularly welcome new team members or clients, having standardised onboarding kits ready to go creates a seamless, professional experience. And for organisations with stable branding and ongoing promotional needs, the convenience of having merchandise on hand whenever opportunity knocks is invaluable.

The numbers speak for themselves – our clients typically save up to 30% on shipping costs alone when choosing bulk orders over multiple smaller batches. That's before we even factor in the per-unit savings!

Advantages of Placing a Bulk Order

The beauty of bulk ordering extends far beyond simple cost savings (though we must admit, those savings are rather lovely). When you commit to larger quantities, you're open uping multiple benefits that can positively impact your brand presence and operational efficiency.

First and foremost, the reduced per-unit price is undeniably attractive. Most suppliers, including Mercha, offer tiered pricing that kicks in around the 100-unit mark, with savings typically ranging from 15-30% compared to smaller orders. Order 250, 500, or 1,000+ units, and you'll often see even more significant discounts. One of our corporate clients, a tech company with offices throughout Australia, told us they've saved approximately 22% since switching to a twice-yearly bulk order strategy.

Beyond the financial benefits, there's something to be said for the consistency that comes with producing all your items in a single run. When your team members are representing your brand at different events, the last thing you want is noticeable variations in your branded merchandise. Bulk production ensures your company blue stays exactly the same shade across all items – no awkward mismatches.

There's also tremendous value in having merchandise ready to go whenever opportunity knakes. Rather than scrambling with rush orders (and rush pricing) when a last-minute event pops up, you can simply reach into your supply and be prepared. This readiness creates a professional impression and allows you to capitalise on unexpected marketing opportunities.

The administrative relief shouldn't be underestimated either. Processing one larger order requires significantly less time and effort than managing multiple small orders throughout the year. Your procurement team will thank you!

Lastly, larger orders often give you more room to negotiate on pricing, customisation options, or delivery specifics. When you're bringing substantial business to a supplier, they're naturally more motivated to accommodate your specific needs.

For more insights on stretching your promotional budget further, check out our guide on Shop at Mercha: Boost Your Brand with Cost-Effective Promotional Items Today.

Potential Drawbacks of Bulk Orders

While bulk orders offer compelling advantages, they're not the perfect solution for every situation. It's important to consider some practical challenges before committing to larger quantities.

Storage space is perhaps the most immediate concern. Those 500 branded t-shirts or 1,000 custom pens need to live somewhere! If your office is already short on space, finding room for boxes of merchandise might prove challenging. We've had clients solve this creatively – from dedicating specific storage areas to occasionally using team members' garages (with permission and compensation, of course).

Design Flexibility Considerations. Bulk orders can limit your ability to adapt to changing brand needs. Imagine ordering 1,000 mugs with your current logo, only to have your company announce a complete rebrand a few months later. Suddenly, those perfectly branded merch become instantly outdated, forcing you to either use them internally or risk presenting inconsistent branding to clients.**

Design changes happen more frequently than you might expect - from subtle color adjustments to complete logo overhauls. With smaller batch orders, you maintain the flexibility to incorporate these changes without being stuck with obsolete branded merchandise.

When planning your order size, always consider your branding roadmap and any potential design changes on the horizon. This foresight can save you from the frustration of watching perfectly good merchandise become obsolete before it's even distributed.

Business priorities and needs evolve constantly, creating a risk that merchandise ordered in bulk might become less relevant before you distribute it all. This is particularly true for items tied to specific campaigns or seasonal promotions.

The larger upfront investment is another consideration. While you'll save money per unit, the total invoice amount is higher, which can create cash flow challenges, particularly for smaller businesses or those with tight budgetary constraints.

Finally, there's the issue of inventory freshness. Products sitting in storage for extended periods might show wear or simply start to look dated compared to newer merchandise styles. This is especially relevant for trendy items or apparel that follows fashion cycles.

These potential drawbacks don't mean you should avoid bulk orders – they simply highlight the importance of thoughtful planning.

Consider your storage capabilities, upcoming branding changes, cash flow situation, and how quickly you'll realistically use the merchandise. With careful consideration, you can determine whether the substantial benefits of bulk ordering outweigh these practical challenges for your specific situation.

Factors to Consider When Choosing Between Bulk Orders and Small Batches

Deciding between bulk orders and small batches isn't just about finding the cheapest per-unit price—it's about aligning your merchandise strategy with your broader business goals and practical realities.

When I sit down with clients to help them make this decision, we walk through several key considerations that can make all the difference between a successful merchandise campaign and one that leaves you with boxes of unused items or scrambling to fulfil last-minute needs.

Your budget constraints naturally play a significant role. While bulk orders require a larger upfront investment, they often save money in the long run. I always encourage clients to consider their total spending over 6-12 months rather than just the immediate cost. One marketing manager I worked with was initially hesitant about a larger order until we calculated that she'd save nearly $3,000 over the year compared to placing multiple small batches.

Storage space is a practical consideration that many businesses overlook. Those 500 branded hoodies need to live somewhere! I remember visiting a client who had stashed their bulk order of promotional items in the office kitchen, much to the dismay of the staff trying to access the coffee machine. Before committing to a large order, be honest about whether you have adequate, clean storage space to maintain product quality.

Your timeline and urgency will often dictate your best option. Small batches typically move through production more quickly—sometimes in half the time of larger orders. When one of our clients needed branded merchandise for a trade show that was just two weeks away, a small batch was their only viable option despite the higher unit cost.

Consider your risk tolerance when it comes to branding changes. How confident are you that your current logo, colours, and messaging will remain consistent? The higher your confidence, the more sense a bulk order makes. I've seen too many businesses stuck with outdated merchandise after a rebranding exercise to ignore this factor.

Your future plans should factor heavily into this decision. A growing tech startup might benefit from the flexibility of small batches as they refine their brand identity, while an established business with stable branding might save significantly with bulk purchasing.

According to our research, businesses that carefully assess these factors before placing orders report 35% higher satisfaction with their merchandise strategy and experience 27% less waste from unused items.

Is a Bulk Order Right for Your Business Needs?

Bulk orders tend to shine in specific situations. If your project scale is large—like outfitting hundreds of conference attendees or launching a major product—the logistics and cost savings of bulk ordering make perfect sense.

Businesses with frequent, predictable usage benefit tremendously from the bulk approach. One of our clients, a national insurance company, orders 1,000 welcome kits annually for new clients. "By switching to a bulk order approach, we've reduced our per-unit costs by 23% and eliminated the stress of rush ordering when we have a surge in new business," their customer relations director told me. "The upfront investment pays for itself within the first quarter."

Stable branding is another green light for bulk ordering. When your visual identity is established and unlikely to change soon, you can confidently order larger quantities knowing they'll remain relevant. This consistency across all your branded items creates a more professional impression too.

When cost savings are a priority—and when aren't they?—the 15-30% discount from bulk ordering can make a significant difference to your bottom line. For businesses working with tight marketing budgets, these savings can free up resources for other initiatives.

Of course, adequate storage is essential. I've worked with clients who secured fantastic bulk discounts only to realise they had nowhere to keep their merchandise. Clean, climate-controlled storage ensures your items remain in perfect condition until they're needed.

When Small Batches Make More Sense

Small batch orders often prove ideal when you're testing the market with new merchandise concepts. A boutique consulting firm I work with ordered just 25 custom journals with a new design before committing to larger quantities. When they received enthusiastic feedback, they confidently placed a larger order, knowing their investment would be well-received.

For seasonal or time-limited promotions, small batches reduce the risk of leftover inventory. There's nothing quite as disheartening as finding boxes of "Summer 2023" branded items taking up valuable storage space when autumn rolls around.

Businesses with limited storage naturally gravitate toward smaller orders. Many of our clients in urban areas with premium real estate costs simply don't have the luxury of space for large merchandise inventories. Small, regular orders work much better for their physical constraints.

When agility is essential to your business model, the flexibility of small batches often outweighs the cost savings of bulk. This is particularly true in rapidly evolving industries or for businesses with changing branding needs. A tech startup founder explained their approach: "As a new company still refining our visual identity, we weren't ready to commit to hundreds of items. The slightly higher per-unit cost was worth it for the flexibility it gave us to evolve our branding as we grew."

Cash flow considerations often favour smaller orders despite the higher unit cost. For growing businesses or those with seasonal revenue fluctuations, spreading merchandise costs throughout the year can be easier to manage than large upfront investments.

For businesses needing merchandise quickly, our guide on Fast Track Your Branding: Rush Order Custom Pens offers valuable insights on getting quality branded items with minimal lead time.

The right choice ultimately depends on your specific business context. By carefully weighing these factors, you'll find the sweet spot that balances cost-effectiveness with practical realities for your unique situation.

How Mercha Simplifies Your Merch Ordering Process

At Mercha, we've taken the complexity out of ordering branded merchandise, whether you're after a small batch or planning a bulk order. We understand that deciding between quantities is just one piece of the puzzle – that's why we've built a platform that makes the entire process refreshingly simple.

We've focused on three key elements that transform the merchandise ordering experience:

First, our easy online ordering system takes you from browsing to checkout in just three steps. No more endless email chains or convoluted quote processes – just select your products, upload your designs, and place your order. It's merchandise ordering reimagined for the digital age.

Second, we're absolutely committed to high-quality products. We've carefully selected each item in our range to ensure it meets our exacting standards. Your brand deserves to be represented on merchandise that looks professional and stands the test of time – whether you're ordering 25 items or 2,500.

Third, our sustainability focus acknowledges that modern businesses care deeply about their environmental impact. We offer an extensive range of eco-friendly options that don't compromise on quality or appearance, helping your brand make a positive impression in more ways than one.

What truly makes Mercha different is our democratic approach to service. Unlike suppliers who reserve their best attention for large orders, we provide the same care and dedication regardless of your order size. As Nikki, one of our regular customers, notes: "The platform just keeps getting better and better. Customer service is always very quick to respond and handle any issues that our customers may have."

Our system automatically calculates appropriate quantity discounts, so you'll always know exactly what you're paying and how much you're saving. For bulk orders, our tiered pricing can reduce your per-unit cost by up to 30% compared to small batch prices – significant savings that go straight to your bottom line.

Featured Products to Get You Started

Whether you're testing the waters with a small order or diving into a bulk order, here are some of our most popular products to consider for your next merchandise project:

Eco-friendly Tote Bags

Our eco-friendly tote bags marry sustainability with style. Made from recycled materials, these versatile bags feature a generous print area that showcases your branding beautifully. The reinforced handles ensure durability, making them perfect for conferences, retail promotions, or employee welcome kits. Available in a variety of colours, you can order quantities from 25 to 10,000+, with significant savings as your quantity increases.

Custom T-Shirts

When it comes to branded apparel, our premium custom t-shirts stand out from the crowd. Available in a wide spectrum of styles, colours, and sizes, these shirts are crafted from high-quality fabrics that maintain their appearance wash after wash. The excellent print results ensure your logo or design looks crisp and professional. Whether you're outfitting your team, event staff, or planning promotional giveaways, you can start with just 10 units, with attractive discounts kicking in for bulk orders of 100 or more.

Starter Merch Packs

If you're looking for a ready-made solution, our Starter Merch Packs take the guesswork out of merchandise selection. Each carefully curated pack includes essential branded items like notebooks, pens, water bottles, and more – all customised with your logo. These convenient packages are ideal for new employee onboarding, client appreciation, or event giveaways. Available in quantities from 10 to 1,000+, each item is selected for its quality and practical value.

For all our products, we provide transparent pricing tiers so you can clearly see how your per-unit cost decreases as your order quantity increases. This clarity helps you make an informed decision about whether a bulk order or small batch makes more sense for your specific needs and budget.

Still Not Sure? Start Small and Scale Up

If you're feeling caught between the appeal of cost-saving bulk orders and the flexibility of small batches, you're not alone. Many of our most successful clients began their merchandise journey with a thoughtful middle-ground approach: starting small and scaling up strategically.

This approach is like dipping your toe in the water before diving in—you get to test the temperature first. By beginning with a carefully selected small batch (typically 25-50 units), you can gather real-world feedback before committing to larger quantities.

The beauty of this strategy is how it combines the best of both worlds. You enjoy the lower risk and flexibility of small batches initially, then graduate to the cost savings of bulk ordering once you've validated your choices. It's a practical, measured approach that just makes good business sense.

One of our Brisbane-based software clients followed exactly this path when launching a new product line. They started with just 30 premium branded notebooks distributed to their sales team and key clients. After receiving enthusiastic feedback about both quality and usefulness, they confidently placed a bulk order for 500 units for their broader marketing efforts.

To implement this approach effectively in your business:

First, be strategic about your initial small batch. Choose items that truly represent the quality and style you're aiming for, rather than the cheapest options available.

Next, distribute your test merchandise thoughtfully to people whose opinions you value—key team members, loyal customers, or trusted industry partners. Random distribution won't give you the focused feedback you need.

Be specific when collecting feedback. Ask recipients about product quality, everyday usefulness, design impact, and overall impression. Document these insights systematically so you can spot patterns.

Pay attention to how people actually use the items in real life. Are those branded notebooks prominent on desks or hidden in drawers? Do team members genuinely wear the branded clothing by choice? These observation insights are often more valuable than what people tell you directly.

Once you've gathered sufficient feedback, refine your approach if needed. Perhaps a different product would better serve your goals, or maybe the design needs tweaking for greater impact.

Finally, when you're confident in your choices, place your bulk order with the assurance that comes from real-world testing. You'll not only save money with volume pricing but also avoid the costly mistake of ordering hundreds of items that don't resonate with your audience.

As one client perfectly summarised: "Starting small let us focus on strategy rather than worrying whether our merchandise choices would hit the mark."

For businesses needing merchandise quickly at any stage of this process, our guide on Rush Hour: Quick Custom Promotional Products for Your Business provides valuable insights on expedited options.

Frequently Asked Questions about Merch Kit Order Sizes

How does order size affect production turnaround times?

When it comes to getting your branded merchandise in hand, timing matters—and your order size plays a significant role in how quickly items arrive at your doorstep.

Small batches (under 100 units) typically move through our production process more swiftly, usually landing in your hands within 1-2 weeks from design approval. This quicker turnaround makes small batches perfect for those "we need it soon" situations that inevitably pop up in business.

For bulk orders of 100+ units, we generally need a bit more time—typically 2-4 weeks from approval to delivery. This longer timeline isn't just about quantity; larger orders require more materials, extended production runs, and more thorough quality checks to ensure every single item meets our standards.

At Mercha, we believe in transparency about timelines. We'll keep you updated throughout the process so you're never left wondering when your merchandise will arrive. And yes, for those truly urgent situations, we do offer rush services on select products (though additional fees may apply).

The golden rule? Plan ahead whenever possible, especially for those major events or campaigns where you'll need substantial quantities. A little foresight goes a long way in ensuring stress-free merchandise delivery.

Can I get bulk discounts on small batch orders?

While the most substantial savings typically kick in at the 100-unit mark, we've structured our pricing to give you cost advantages even on smaller orders. Think of it as "mini-bulk" pricing that rewards you for ordering just a bit more, without requiring a massive commitment.

For example, you might see a branded notebook priced at £12 each for 10-24 units, then drop to £10 each when you order 25-49, and further reduce to £8 each for 50-99 units. The full bulk order discount at 100+ units might bring it down to £6 each. This stepped approach means you can access proportional savings regardless of your order size.

We also offer bundle discounts when you order multiple different products at the same time, even in smaller quantities. It's our way of helping you achieve some cost efficiency while still maintaining the flexibility that smaller orders provide.

After all, we understand that not every business needs 500 identical items—sometimes you just need 30 quality branded notebooks for your sales team, and we want to make that as cost-effective as possible.

What if I need my merch kits urgently?

We've all been there—that moment when you suddenly realise you need branded merchandise for an event that's coming up much sooner than you'd planned. Don't worry, we've got options to help you out of that tight spot.

For those urgent requirements, we offer several solutions to get quality merchandise in your hands quickly:

Our rush production services can cut standard production times by up to 50% for an additional fee. For truly time-sensitive situations, we maintain an inventory of popular products that can be customised and shipped within 48-72 hours.

If you've placed a bulk order but need some items immediately, we can often arrange partial shipments—sending a portion of your order early to meet your immediate needs, with the remainder following on the standard timeline.

For some products, we can tap into our network of local Australian manufacturing partners to significantly reduce shipping times. This local production option has saved the day for many of our clients facing tight deadlines.

It's worth noting that rush services are generally easier to accommodate for smaller batches than for large bulk orders—another factor to consider when deciding between order sizes. However, with adequate planning, even large orders can be fulfilled on accelerated timelines when necessary.

For the most current information on rush options and timelines for your specific needs, I'd recommend reaching out to our team directly. We're quite good at finding creative solutions to timing challenges!

Merch That Speaks for Your Brand

You've now explored both sides of the bulk order versus small batch debate, and hopefully have a clearer picture of which approach aligns best with your unique business needs. The beauty of merchandise ordering is that there's no universal right answer—it's all about finding the perfect fit for your specific situation.

Many of our most successful clients actually use a blend of both strategies. They'll place bulk orders for their everyday essentials like branded pens and notebooks that never go out of style, while experimenting with small batches for seasonal campaigns or when testing out new product lines. This hybrid approach gives them the best of both worlds: cost efficiency where it counts and flexibility where they need it.

At Mercha, we're committed to supporting your branded merchandise journey regardless of which path you choose. Whether you're a startup ordering 25 premium tote bags or a national corporation needing 5,000 custom t-shirts for a product launch, our platform makes the process straightforward and stress-free.

What truly matters isn't just how many items you order, but the quality, relevance and impact of the merchandise itself. We've seen small, thoughtfully selected batches create lasting impressions just as powerful as comprehensive bulk order campaigns. The key is choosing items that genuinely represent your brand values and provide real utility to recipients.

Ready to get your next merchandise project underway? Visit Mercha.com.au to explore our full range of customisable products. Our intuitive platform walks you through the entire process in just three simple steps, from product selection to design upload and checkout.

Still weighing up your options? Our team is always happy to chat through your specific needs and help you determine the ideal order size for your circumstances. We might recommend starting with a strategic small batch that you can scale up once you've seen how your team or customers respond.

With Mercha as your merchandise partner, you can feel confident that your branded items will make the right impression, build meaningful connections, and strengthen your brand—whether you're ordering 10 items or 10,000.