As a non-staffer but someone who does have knowledge about the imprint industry:
Shirt.woot’s printing process hasn’t changed since fully moving to DTG over 5 years ago. A pretreatment is sprayed onto the shirt blanks (via machine), which helps the ink bond to the fabric. After it prints, the shirt is ran through a tunnel dryer to cure the ink.
Alas, if the pretreatment was not applied evenly (a clogged sprayer) or it did not absorb all that well into the fabric (which mostly being cotton, can vary from batch to batch), it can yield a print with poorer durability. It’s not an aspect that’s readily visible during the printing and inspection – it’ll look fine, but ends up not holding up like it should.
Going by the hundreds I’ve purchased, I have to say the majority are fine. Yes, some do have wear here and there, but the last two I retired were due to holes in the shirt, not worn off print. The only aspect I do is flip them inside-out before going into the washer; my old shirts that were printed on American Apparel gets line dried; the rest go through the dryer.
Is there anything that could be changed? Not really; the other option, which would be to manually spray the pretreatment, is less consistent due to the human factor. The last time I had a horrible print was a few years ago when the ink wasn’t fully cured on the shirt before it got folded up and shipped off. It took a couple rounds with CS, but I got replacements.