From DIY to Done: My 5-Year Journey to Perfecting Belly Bands for My Products
When I started selling my own products, I quickly realized that packaging matters just as much as the product itself. Belly bands—those sleek, branded wraps that hold everything together—became an essential part of my product presentation. But figuring out how to produce them efficiently took me on a five-year journey of trial, error, and finally finding the perfect solution.
If you're struggling with printing your own packaging, outsourcing production, or managing costs, I’ve been there. Here’s my journey, the lessons I’ve learned, and the insights that might help you streamline your packaging, too.
Phase 1: DIY Belly Bands – Learning the Hard Way
Like many small business owners, I started with a DIY approach. I wanted control over the design, costs, and timing. My process looked something like this:
Printer of choice: Canon Pixma Pro-100
Paper stock I used: Basic printer paper- 8.5 x 11
Cutting and assembly process: I invested in a slide cutter from Office Max, it was maybe $15 at the most.
The biggest pain points: I made them way too tall for my towel. The designs were hidden. They also didn’t have any pop or anything on them that made you want to pick them up and look closer.
While this worked for small batches, as my orders increased, I quickly realized:
The quality was inconsistent
Printing was time-consuming and expensive
Cutting everything by hand was a nightmare
That's when I knew I had to explore outsourcing.
Phase 2: The First Outsourcing Attempt – This was the dream… until it wasn’t, lol.
Once I decided to outsource, I thought it would be simple—find a printer, send my files, and receive a perfect product. The problem was one I created myself. I wanted an individual belly band for each towel that I had. That meant that I was ordering a ton of belly bands for my growing line.
First vendor I tried: Printswell Fullfillment, they are fantastic!
What went amazing: Their printing was consistent and the cost per belly band was low with low minimum orders.
Lessons learned:
It is easier for me longterm to have one belly band for all my towels.
I was still spending a ton of time packaging my towels and started to dream of having my towels delivered ready to ship!
This phase totally worked, but I knew I needed to keep refining my process.
Phase 3: Finding the Right Printing Partner
After a total forehead slap moment, I realized I should try and source my packaging through my tea towel supplier in China. Here’s what I asked my manufacturing partner:
Paper quality: What paper stocks did they have available? They had quite a few options that they used already for belly bands.
Color accuracy: What type of color profile did they need me to submit my work in?
Minimum order quantities (MOQs): How many belly bands would I have to purchase up front? For my supplier I needed to order 1000! However, they would ship me the extras so I could use them in packaging for towels I currently had in stock. So, that wasn’t too intimidating considering it would make all my branding consistent!
Packaging: Would I have to assemble them or could they do it for me in the process of doing my order? Turns out they would take care of all of it! WINNING!
Pricing & bulk discounts: The price per belly band was way less money in the long run compared to me printing my own at home.
After switching to my towel supplier, I immediately saw the benefits below… but it came with one hiccup:
💡 Less stress—No more late-night packaging and assembly
💡 Consistent branding—Every product looked polished and professional
💡 Saved money in the long run—Even though I paid upfront, bulk pricing was cheaper than DIY
However… when I recieved my first complete order with the belly bands… they were all assembled upside down… sigh. A quick fix, but still required my time as I packed orders to fix the band.
Phase 4: The Complete Product—Packaging That Sells
Now, my belly bands are just one piece of a fully polished packaging system that enhances my product. Here’s how I put it all together. Now my supplier has my belly band file, I communicated the direction I want them packaged and I am receiving ready to sell tea towels with each order. This is the dream!
I wish I had outsourced sooner, but this journey taught me valuable lessons about scaling a product-based business, finding trustworthy vendors, and prioritizing efficiency. When I started, 1000 belly bands would have scared me. I needed to learn and grow to get to this spot and I’m thankful for all the lessons learned!
Key Takeaways for Other Business Owners
If you're still hand-printing belly bands or stuck in the outsourcing struggle, here’s my best advice:
🖨️ Start small but plan for growth. If you’re printing at home, test outsourcing before you scale.
🔍 Vet your suppliers. Ask for samples and read reviews before committing.
💰 Compare pricing beyond just the per-unit cost. Factor in ink, paper, labor, and potential waste.
📦 Think beyond belly bands. Your entire packaging should work together to create a premium unboxing experience.
If you’re looking for a great vendor to print your belly bands in the USA, I highly recommend Printswell Fullfillment. They’ve helped me transform my packaging from a DIY mess into a professional, polished look that makes my products stand out.