 Re: Bleeding Thread
The Madeira is as good a rayon thread as there is but it is still rayon and prone to bleeding however, most bleeding like that is because of improper washing. Folks throw the shirt in the washer, head off to work and the wet shirt sits there all day. Of course it will bleed under those circumstances. And who knows what bleech was used since it is a white shirt. But you still are left with a "situation."
The best way to handle it is to be proactive. Do not agree to replace the polos without seeing them ALL. In all likelihood, there are one or two that bled and the rest are just fine. If you find that they ALL bled, I think you're stuck. If you find it is one or two, turn it back on the customer - offer to replace the few bad one "even though it is likely a care problem, not a defect."
All of the heavy dye colors, forest green, maroon, orange etc, can be a problem. You're already using the best rayon thread there is but...
The lesson to be learned in commercial embroidery - POLYESTER THREAD! and emphasis on proper care and washing instructions. | 
