Elevating Souvenir Merchandise: Zagreb Airport’s Organic AOP Tees

When travelers step into the retail stores at Zagreb Airport Franjo Tuđman, they are looking for a piece of Croatia to take home. But modern souvenir buyers expect more than just a colorful print. They want premium comfort, sustainable materials, and genuine quality that lasts well beyond their flight home.

To meet the high standards of airport retail, we partnered with local retail vendors to re-imagine the iconic Croatian checkerboard (šahovnica) t-shirt. Instead of taking the shortcut of cheap polyester sublimation, we built an eco-friendly, 100% organic cotton AOP garment from scratch in our Croatian facility.

Here is an inside look at how we combined organic textiles, revolutionary Kornit printing, and local craftsmanship for Zagreb Airport's retail lineup.

Breaking the Mold: Why We Skipped Synthetic Fabrics

Walk into almost any souvenir shop worldwide and you will find All-Over Print (AOP) shirts made from 100% synthetic polyester. While polyester is easy to print, it lacks breathability, retains body odor, and often feels rigid against the skin,which is hardly ideal for long travel days.

We decided to flip the script by engineering our custom 180 GSM Single Jersey knit made from 100% GOTS-certified organic cotton. Natural cotton is notoriously difficult to print edge-to-edge, but its soft hand-feel, hypoallergenic properties, and natural breathability make it vastly superior for high-end retail apparel.

The Game-Changer: Water-Based Kornit Pigment Printing

How do we achieve deep, vibrant red checkerboards and crisp details on a natural cotton roll without heavy chemicals?

The answer lies in our Kornit digital roll-to-roll machinery. Using state-of-the-art water-based pigment inks, we print full-coverage designs directly onto raw organic cotton fabric rolls before any cutting takes place.

• Zero Plastic Feel: Unlike traditional screen prints that create a thick, rubbery layer on the chest, pigment printing penetrates deep into the organic cotton fibers, leaving the finished garment completely breathable.

• Non-Toxic & Sustainable: The entire digital process uses zero harmful chemicals and a fraction of the water consumed by conventional dyeing methods, meeting strict global environmental criteria.

Behind the Seams: From Printed Roll to Airport Shelves

Printing the fabric is only the first step. To ensure the iconic Croatian coat of arms and red-and-white checkerboard look flawless on every size, our production team follows a strict in-house workflow:

1. Automated Precision Cutting: Geometric patterns like checkerboards demand exact alignment. Our automated cutting machinery slices the printed fabric into perfect panels, preventing pattern distortion across the seams.

2. In-House Sewing Assembly: Our experienced seamstresses assemble the panels in our Croatian facility, applying double-stitched hems for heavy-duty retail durability.

3. Dual-Label Premium Finishing: Scratchy, oversized neck tags have no place in luxury organic apparel. To achieve a clean, retail-ready finish, we use a two-step labeling process: we print our logo and website URL directly inside the collar using soft, water-based DTG printing for itch-free comfort, and insert a custom-made satin care label into the seam for exact fabric composition and washing instructions.

Bring Unique European All-Over Print Products to Your Gift Shop

Looking to stand out from generic tourist merchandise? Beyond airport travel hubs, our Croatian facility produces custom eco-friendly AOP t-shirts for souvenir shops, gift galleries, and boutique retailers across Europe.

We combine 100% GOTS organic cotton fabrics with zero-chemical Kornit pigment printing to give your store a truly premium, sustainable garment lineup that travelers actually want to wear.

Get in touch with our team or register today to discuss custom souvenir designs, request samples, or start your first order with a minimum of just 1 piece!

See It in Action!

Want a closer look at the finished product and our finishing touches? Watch our short Instagram Reel to see the DTG neck label printing process live and check out how the final organic AOP t-shirt looks!

Frequently Asked Questions (FAQ)

Q: What makes cotton AOP different from standard sublimation?
A: Sublimation only works on polyester fabrics. Our Kornit pigment printing allows full-coverage AOP printing directly onto 100% organic cotton, offering true breathability and a natural fabric feel.

Q: Why is GOTS certification important for retail merchandise?
A: GOTS guarantees that the cotton is grown without toxic pesticides and processed under fair, eco-friendly conditions. It gives your retail customers verifiable proof of sustainability.

Q: Is there a minimum order quantity (MOQ) for custom AOP t-shirts, and how can we order?
A: Because we manufacture everything in-house, our minimum order quantity is just 1 piece. Since All-Over Print (AOP) requires custom pattern alignment across raw fabric rolls, AOP designs cannot be configured directly through our online product builder. To order custom AOP t-shirts or request a template, simply contact our team via email with your design files and requirements, and we will guide you through the process.

Q: Can we customize internal neck labels with our own branding?
A: Yes! We print soft, tagless neck labels directly inside the garment collar using non-toxic water-based DTG inks during final finishing.