Minimum order quantities are the usual issue.
There's way much more to it than that. I'm lucky in that my wife is a print specialist and she guided me through our early forays in merchandise. Without her advice our shirts would probably be the same sort of lacklustre digi-print items that other clubs knock out. Hands up how many members are still wearing club t-shirts many years after they bought them, lots I'm guessing. We went for the quality route and to do this you need to pre-order set amounts of kit. We stuck with screenprinting because it gives the best quality, but you can't order 4 shirts at a time, you have to order a batch to make the price attractive. Digi-printed shirts are cheap, can be ordered in ones or twos, but will not last beyond a couple of years.
I'm not sure we've had a problem with merchandise, other than the fact that we haven't renewed our stocks for while. What we had sold well and was well-made.
Funding the club through merchandise is a risky venture. Merchandise can supplement the funds, but sometimes, if the stock lays unsold, it can deplete resources. Trust me, I know. The subs are the only guaranteed way to meet costs.
I'll do a bit of calculating later and get back to you on what the two rates of membership are likely to be. In each case the amount will cover costs and no more. As I have said, we cannot consider operating the club without PLI cover and, from experience, the most effective (and cheapest) way of getting this is via MAG or the BMF. Let's see what the subs will be before getting het up about PLI.
GC