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i've seen this happen before and it has typically been the encoder strip. Usually dirty and needs cleaned or replaced.
rollers likely cause of media skew as well
you'll have no problem with heat pressing...as other say just put a tefon sheet, pillow or thread the heat press with the garment to avoid it sticking to the other side of jersey
the likely reason you are seeing this is because the particular material you are using is thin and has stretch and rebound qualities. My guess you are printing on a 100% cotton t-shirt...washing and drying. What is happening the shirt is shrinking somewhat and the transfer material is conforming...
CMYK Lc Lm Lk is the way to go for sure with the new "i" models. Print quality really is amazing with it.
I wouldn't add white or metallic unless you absolutely know you will use it. It is a nice option and does a great job when printed, it just is very niche.
imprintables carries the patterns and are available by the yard...
stahls ID or transfer express can create transfers for you as well if you need large quantities.
tajima and barudan are your top two out there. i cant speak on using either, but out of the number of folks we see at the ISS and printwear show, these are the two people are mainly using. all positive reviews from both
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