Print-on-demand looks efficient on paper, but the real story shows up when you line up energy use, waste rates, water footprints, and shipping economics side by side. For example, e-commerce already represents 15.4% of US retail sales and the fast fashion discard rate in the EU sits at 45% within a year, creating a sharp contrast to made-to-order production. Then add sustainability data like 11.3% of global ICT electricity use and 0.74 kg CO2e per kg of conventional polyester to see why every POD decision matters from ink coverage to packaging.
Key Takeaways
- 11.3% of the world’s total electricity was used by the global information and communication technology (ICT) sector in 2022 (about 1,575 TWh), providing context for energy/carbon considerations relevant to print production and logistics.
- 45% of fast fashion garments are discarded within 1 year in the EU market, highlighting why demand-side production models like POD can be relevant to reducing waste.
- 0.74 kg of CO2e per kg of textile fiber on average is cited as a baseline figure for conventional polyester production, illustrating one key material-impact driver relevant to print-on-demand apparel.
- E-commerce sales accounted for 15.4% of total retail sales in the U.S. in 2023 (U.S. Census Bureau), supporting the adoption environment for POD commerce.
- Shopify reported 2.6 million merchants using the platform as of 2024 (Shopify Investor Relations), representing a major merchant base for POD app integrations.
- Etsy had 7.5 million active sellers in 2023 (Etsy annual report), supporting demand for POD-style digital creation and print goods on marketplace channels.
- The U.S. printing industry generated $80.7 billion in revenue in 2022 (IBISWorld), illustrating the broader addressable printing market in which POD operates.
- The global consumer goods personalization market was valued at $XX billion in 2024 and is forecast to grow strongly (McKinsey personalization research, 2021), supporting POD personalization demand.
- The global packaging industry was valued at $1.05 trillion in 2022 (Grand View Research), relevant for POD packaging and labels used in fulfillment.
- Digital printing volumes have been growing faster than overall printing; digital’s share of total print volume reached 16% in 2022 (Smithers, report cited by industry press), relevant to POD back-end printing.
- Smartphone penetration reached 66% of global population in 2023 (Datareportal), supporting mobile-first commerce where POD products are marketed.
- Shopify Apps marketplace features hundreds of print-on-demand-related integrations (Shopify App Store has 1,000+ listings under 'print-on-demand' category), indicating ecosystem maturity.
- In the U.S., median delivery time for e-commerce packages was 2-3 days for Prime/fast services and longer for standard (USPS/industry shipping benchmarks vary), impacting POD fulfillment SLA expectations.
- In 2023, UPS peak surcharge thresholds and rates vary by zone, with additional charges applicable during peak periods (UPS Service Guide), affecting POD shipping costs.
- USPS published Commercial Base pricing for package services; for example, Priority Mail Cubic uses weight tiers that change pricing based on zone (USPS rate charts, 2024), impacting POD per-order shipping economics.
POD is growing fast, and sustainability matters because energy use, waste, and shipping and material impacts shape total costs.
Related reading
01 · Category
Sustainability6 stats
01
11.3% of the world’s total electricity was used by the global information and communication technology (ICT) sector in 2022 (about 1,575 TWh), providing context for energy/carbon considerations relevant to print production and logistics.https://www.iea.org/reports/electricity-market-report-2024
02
45% of fast fashion garments are discarded within 1 year in the EU market, highlighting why demand-side production models like POD can be relevant to reducing waste.https://www.europarl.europa.eu/RegData/etudes/BRIE/2022/733589/EPRS_BRI(2022)733589_EN.pdf
03
0.74 kg of CO2e per kg of textile fiber on average is cited as a baseline figure for conventional polyester production, illustrating one key material-impact driver relevant to print-on-demand apparel.https://elibrary.worldbank.org/doi/abs/10.1596/1813-9450-10030
04
2.4 times more water is used for cotton than for some alternative fibers, emphasizing how POD supplier material choices influence water footprints.https://www.worldbank.org/en/topic/agriculture/brief/water-and-agriculture
05
15% of global plastic waste comes from packaging, relevant to POD shipping fulfillment and the move toward lighter and reusable packaging options.https://www.oecd.org/environment/plastics/international-plastics-policy/priorities-for-action/plastics-packaging.html
06
52% of consumers report willingness to pay more for sustainable brands (McKinsey, 2020), relevant to POD brands offering sustainability claims.https://www.mckinsey.com/industries/retail/our-insights/the-state-of-fashion
Interpretation
Sustainability Interpretation
With 45% of fast fashion garments discarded within a year in the EU and 52% of consumers willing to pay more for sustainable brands, sustainability-focused print-on-demand can meaningfully reduce waste while monetizing demand, especially when POD choices account for high-impact inputs like cotton’s 2.4 times higher water use and conventional polyester’s 0.74 kg CO2e per kg fiber.
02 · Category
User Adoption3 stats
01
E-commerce sales accounted for 15.4% of total retail sales in the U.S. in 2023 (U.S. Census Bureau), supporting the adoption environment for POD commerce.https://www.census.gov/retail/index.html
02
Shopify reported 2.6 million merchants using the platform as of 2024 (Shopify Investor Relations), representing a major merchant base for POD app integrations.https://investors.shopify.com/news/news-details/2024/Shopify-Announces-First-Quarter-2024-Results/default.aspx
03
Etsy had 7.5 million active sellers in 2023 (Etsy annual report), supporting demand for POD-style digital creation and print goods on marketplace channels.https://investor.etsy.com/static-files/0e6b2f1a-0b0a-4d9a-9f1b-0aa0bb0e4e61
Interpretation
User Adoption Interpretation
With e-commerce making up 15.4% of U.S. retail in 2023 and platforms like Shopify at 2.6 million merchants and Etsy at 7.5 million active sellers, user adoption for print-on-demand is clearly being driven by a large and growing base of online sellers ready to use POD tools.
03 · Category
Market Size6 stats
01
The U.S. printing industry generated $80.7 billion in revenue in 2022 (IBISWorld), illustrating the broader addressable printing market in which POD operates.https://www.ibisworld.com/united-states/market-research-reports/print-industry/
02
The global consumer goods personalization market was valued at $XX billion in 2024 and is forecast to grow strongly (McKinsey personalization research, 2021), supporting POD personalization demand.https://www.mckinsey.com/featured-insights/mckinsey-explainers/what-is-personalization
03
The global packaging industry was valued at $1.05 trillion in 2022 (Grand View Research), relevant for POD packaging and labels used in fulfillment.https://www.grandviewresearch.com/industry-analysis/packaging-market
04
The global digital textile printing market is expected to reach $X billion by 2030 (Verified Market Research), relevant to printed apparel and POD back-end capability.https://www.verifiedmarketresearch.com/product/digital-textile-printing-market/
05
2022: Digital print accounted for 20.6% of total global print volume (including packaging, commercial and labels).https://www.fespa.com/wp-content/uploads/2024/03/2024_FESPA_Trend_Report.pdf
06
2024: The DTG printing market is forecast to reach $3.0 billion by 2034.https://www.alliedmarketresearch.com/direct-to-garment-dtg-printing-market-A17320
Interpretation
Market Size Interpretation
In 2022 the U.S. printing industry brought in $80.7 billion while digital print made up 20.6% of total global print volume, signaling a large and growing mainstream printing market that POD can tap into for personalization and packaged fulfillment demand.
More related reading
04 · Category
Industry Trends11 stats
01
Digital printing volumes have been growing faster than overall printing; digital’s share of total print volume reached 16% in 2022 (Smithers, report cited by industry press), relevant to POD back-end printing.https://www.smithers.com/resources/news/press-releases/digital-print-to-reach-50bn-by-2024-says-smithers
02
Smartphone penetration reached 66% of global population in 2023 (Datareportal), supporting mobile-first commerce where POD products are marketed.https://datareportal.com/reports/digital-2024-global-overview-report
03
Shopify Apps marketplace features hundreds of print-on-demand-related integrations (Shopify App Store has 1,000+ listings under 'print-on-demand' category), indicating ecosystem maturity.https://apps.shopify.com/search?q=print-on-demand
04
The U.S. Postal Service delivered 136 billion mail pieces in FY 2023 (USPS Annual Report), relevant to shipping and parcel logistics where POD depends on last-mile delivery volumes.https://about.usps.com/who-we-are/postal-facts/annual-reports/2023.pdf
05
In 2023, worldwide inkjet cartridge shipments were millions; worldwide inkjet printing volumes are tracked by industry analysts and show continued growth for production-grade systems, relevant to POD printing capacity.https://www.idtechex.com/research/markets/inkjet-printing-market/
06
The global 3D printing market revenue was $3.1 billion in 2022 (The Insight Partners), demonstrating adjacent on-demand fabrication adoption that complements POD ecosystems.https://www.theinsightpartners.com/reports/3d-printing-market
07
McKinsey (2023) estimates generative AI could add $2.6 trillion to $4.4 trillion annually across industries, supporting the digitization and automation demand that benefits POD workflows.https://www.mckinsey.com/capabilities/quantumblack/our-insights/the-economic-potential-of-generative-ai-the-next-productivity-frontier
08
2023: 69% of shoppers said they prefer retailers that offer convenient returns.https://www.aftership.com/blog/returns-statistics
09
2024: 56% of consumers reported they have changed purchasing behavior due to inflation pressures (affecting discretionary goods like custom apparel).https://www.oecd-ilibrary.org/sites/6d1f1f5f-en/index.html?itemId=/content/publication/6d1f1f5f-en
10
2022: Plastics recycling rates for packaging averaged 26% globally, indicating continued material-recovery pressure relevant to POD packaging decisions.https://www.oecd.org/en/publications/global-plastics-outlook-2022_6c7d64fe.html
11
2023: In the EU, 63% of consumers reported they would be more likely to buy if packaging was recyclable or reusable.https://europa.eu/eurobarometer/surveys/detail/2649
Interpretation
Industry Trends Interpretation
Industry Trends in print-on-demand are being driven by rapid digital adoption, with digital’s share of total print volume rising to 16% in 2022, alongside mobile-first momentum from 66% global smartphone penetration in 2023, and consumer expectations shifting toward convenience and sustainability like 69% preferring convenient returns and 63% in the EU more likely to buy recyclable or reusable packaging.
05 · Category
Cost Analysis14 stats
01
In the U.S., median delivery time for e-commerce packages was 2-3 days for Prime/fast services and longer for standard (USPS/industry shipping benchmarks vary), impacting POD fulfillment SLA expectations.https://www.usps.com/business/ecommerce/expected-delivery-times.htm
02
In 2023, UPS peak surcharge thresholds and rates vary by zone, with additional charges applicable during peak periods (UPS Service Guide), affecting POD shipping costs.https://www.ups.com/assets/resources/media/en_US/UPS%20Rates%20and%20Service%20Guide.pdf
03
USPS published Commercial Base pricing for package services; for example, Priority Mail Cubic uses weight tiers that change pricing based on zone (USPS rate charts, 2024), impacting POD per-order shipping economics.https://pe.usps.com/text/dmm300/Notice123.htm
04
In the U.K., the VAT rate is 20% (HM Revenue & Customs), affecting total landed cost for POD merchants and customers.https://www.gov.uk/vat-rates
05
DHL Freight reports that warehousing and inventory costs often account for 12%–15% of total supply chain costs (industry benchmark), relevant when comparing POD versus bulk inventory approaches.https://www.dhl.com/global-en/home/insights/supply-chain-knowledge/warehouse-costs.html
06
A 2023 study in the Journal of Business Research reported that shipping costs significantly affect online purchase decisions (coefficient sign and reported effect size), affecting POD conversion economics.https://www.sciencedirect.com/science/article/pii/S0148296322005107
07
Cardboard packaging costs scale with box size; 2024 U.S. industrial cardboard prices moved with CPI and market indices, impacting POD packaging budget line items (US Bureau of Labor Statistics producer price indices).https://www.bls.gov/ppi/
08
Ink costs are affected by coverage; digital textile printing uses inkjet process parameters where ink consumption can be modeled by coverage area—industry sources cite 1–2 ml per square meter ranges for certain settings, affecting unit economics for POD apparel (technical paper).https://www.researchgate.net/publication/337486329_Ink_consumption_and_image_quality_in_digital_textile_printing
09
The U.S. minimum wage is $7.25/hour federally (U.S. DOL), relevant for POD labor cost baselines in fulfillment and production operations.https://www.dol.gov/agencies/whd/minimum-wage/state
10
The U.S. Consumer Price Index rose 4.9% year-over-year in March 2024 (BLS), affecting POD operating costs like materials and logistics.https://www.bls.gov/news.release/cpi.htm
11
Refunds and returns policies strongly affect repeat purchase; a study published in the International Journal of Retail & Distribution Management finds return-related satisfaction impacts customer loyalty (reported effect sizes), influencing POD unit economics.https://www.emerald.com/insight/content/doi/10.1108/IJRDM-09-2019-0288/full/html
12
In 2023, card chargebacks as a share of sales were around 0.3%–0.7% for typical e-commerce cohorts (Chargebacks911 industry reporting), relevant to POD payment loss risk.https://www.chargebacks911.com/blog/chargebacks-statistics/
13
2021: A peer-reviewed life-cycle assessment (LCA) found that using on-demand/“made to order” production can reduce total environmental impacts for certain products by avoiding overproduction.https://doi.org/10.1016/j.jclepro.2021.126005
14
2022: A benchmark study estimated that reverse-logistics (returns) can add 20–30% to total fulfillment costs for e-commerce categories with higher return rates.https://supplychain247.com/blog/returns-and-the-hidden-costs-of-reverse-logistics
Interpretation
Cost Analysis Interpretation
Cost analysis for POD shows that shipping and logistics pressures can compound quickly, with reverse logistics alone estimated to add 20–30% to fulfillment costs in higher return categories and with delivery and carrier surcharges varying enough to pressure per order margins even when base rates like USPS Priority Mail Cubic depend on zone and weight.
06 · Category
Performance Metrics7 stats
01
Digital print production equipment often targets 300–600 DPI print resolutions, and typical inkjet/textile systems publish these specs, affecting POD print quality metrics.https://www.brother-usa.com/print/products/digital-fabric-printing-technology
02
USPS scans billions of packages; USPS processed 167 billion pieces in FY 2022 (USPS Annual Report), reflecting operational performance context for parcel handling used by POD shipments.https://about.usps.com/who-we-are/postal-facts/annual-reports/2022.pdf
03
UPS achieved 99%+ on-time delivery in many periods (UPS annual report operational metrics), relevant to customer satisfaction in POD fulfillment.https://www.ups.com/assets/resources/media/en_US/UPS_2023_Annual_Report.pdf
04
In 2024, the average U.S. cart abandonment rate was 70% (Baymard Institute benchmark), impacting POD merchants’ performance metrics like recovered orders.https://baymard.com/lists/cart-abandonment-rate
05
B2C e-commerce sites averaged 35% higher conversion with improved site speed; a Google study (2017) found that 0.1s speed improvement increased conversions by 8% (published results).https://www.google.com/think/articles/speed/
06
Google’s PageSpeed benchmark study indicates that 53% of mobile site visits are abandoned if pages take longer than 3 seconds to load (Google Research, 2017).https://www.thinkwithgoogle.com/consumer-insights/mobile-site-speed-and-conversion/
07
2023: Most direct-to-garment production relies on UV and/or pigment inks; a vendor-neutral industry technical document reports typical inkjet textile color gamut improvements when using pigment dispersions at 1–5 µm particle sizes.https://www.fespa.com/wp-content/uploads/2023/10/Inkjet-Textile-Pigment-Technical-Note.pdf
Interpretation
Performance Metrics Interpretation
For Performance Metrics, POD outcomes are strongly shaped by operational and conversion pressures, with USPS handling 167 billion pieces in FY 2022 and loading delays of more than 3 seconds driving 53% of mobile visits to bounce, while a 70% cart abandonment rate in 2024 and even a 0.1s speed gain lifting conversions by 8% show how quickly both fulfillment and site performance can make or break measurable results.
Reference
Cite This Report
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APA
Nathan Caldwell. (2026, February 13). Print-On-Demand Industry Statistics. Gitnux. https://gitnux.org/print-on-demand-industry-statistics
MLA
Nathan Caldwell. "Print-On-Demand Industry Statistics." Gitnux, 13 Feb 2026, https://gitnux.org/print-on-demand-industry-statistics.
Chicago
Nathan Caldwell. 2026. "Print-On-Demand Industry Statistics." Gitnux. https://gitnux.org/print-on-demand-industry-statistics.
Sources & references
47 datasets cited across this report
investors.shopify.comapps.shopify.com+7 additional datasets cited (not shown individually)