Degrease Screens Pre-Press procedures o All new screens received must be degreased to minimize pin holes and maximize emulsion adhesion. o Product: BIO-1 Ink Wash/Degreaser Coat screens with Emulsion: o One Coat on the inside and one coat on the outside o Product: Saatichem Textil PV Emulsion o Drying time: 45 min. w/ Heated Fan o Drying time: 2 hrs w/fan (Air dry) Artwork separation & Print out o Photoshop, Illustrator or Corel Draw o Color Separator Program: T-Seps or Separation Studio o Printer: Epson WF7010 or Aritsan 1430 o Film Positive: Inkjet WP Film 11x17 or 13x19 o Print on rough side of the film Exposing positive (Burn image) o Measure distance where design should be placed: Front center designs can be: 4inches from neck line Back center designs can be: 5-6inches from neck line o Exposure time: 90 secs. o Rinse with water until image develops o Place near the fan to dry, approx. drying time: 20-30min.
On-Press procedures Use masking tape to tape around all 4 sides of the screens, front and back. o Product: TAPE2T Masking Tape 2 x 60yard Roll o Evaluate screens for any pin holes or imperfections Load screen onto the press o Sequence: Widest image to Smallest o Center screens o For multi-color designs, use micro-registration o Tape away pin holes or use Print First Color down on Test Squares o Print Flash o Register next color and follow sequence: Print-Flash o Once job is checked and approved: Tape up Registration marks Proceed to load shirts and print job. Check Dryer temp and speed is set correctly o Use Temp Test gauges if setting were changed to verify temp is correct. o Correct Curing Temp for Plastisol is: 320 F
Post Production When production is finished, follow these simple steps to maintain a clean and organized shop. Scoop away residual ink from the screen and return to container Spray & Wipe residual ink with Press Wash or Screen Opener o Product: ProWash Press Wash o Product: Screen Opener /Aerosol can Remove Tape & take screens to reclaim area o Rinse with water & Spray Product: BIO-1 Ink Wash o Brush and rinse with water o Rinse with water & Spray Product: ER-188 Emulsion Remover o If using ER-130 Concentrated Emulsion Remover, follow mixing: 1part:10parts water o Brush and rinse with water o If any INK stains remain (aka: Ghost Images) o Apply Bio-1, scrub with brush and rinse with water o Bio-1 works as a degreaser o Put away screens to dry near the Fan or Outside to air dry.
List of Products Film /Art Department Film Inkjet WP 13x19 pack Inkjet ink: UV Blocking Black Scotch Tape Clear Screen Dept. Alum Screens 20x24 Ink Dept. o 40ct Mesh = Glitters/Crystalina o 83ct Mesh = Metallic Inks o 110ct Mesh = White Ink o 125ct Mesh = White Ink & Colors o 156ct Mesh = Colors o 180-200ct Mesh = Fine lines and thinner ink deposit o 230ct- 305ct Mesh = 4color Process Plastisol Inks: Standard Colors, Black & White o White: Cotton White for 100% Cotton & 50/50% o White: Poly White for 100% Polyester garments o 4/C Process Colors: Cyan, Magenta, Yellow & Black Waterbase & Discharge Inks o Discharge Colors or Clear Base o Discharge Activator, Add: 7-10% Additives/Modifiers: o Stretch Additive = Lycra & Spandex Add: 20% o Nylon Catalyst = Nylon Jackets Add: 10% o Curable Reducer = to thin down the inks Add: 20% o Soft Base = Soften Plastisol feel Add: 15%
Press Squeegees 16, 14, 12 & 4 (for left chest) Adhesive: ALBACHEM MIST Adhesive (Aerosol) Adhesive: Waterbase Pallet Adhesive (Liquid) Press side Cleaner: Screen Opener or ProWash liquid Plastic Ink Spatulas Test Squares 15x15 Black or White Darkroom Scoop Coater 16 wide for 20x24 screens Emulsion: Saatichem Textil DW Paper Towel Finish S1 Red Blockout TAPE2T Masking Tape 2 wide Reclaim Dept. Blue or Red Brushes BIO-1 Ink Wash/Degreaser ER-130 Emulsion Remover Sprayers & Bottles
Cost Analysis Supplies Cost: color or screen Item Cost Emulsion $0.90 $20 /quart Tape $0.09 $3.50 /roll Film /Toner $0.85 Laser Film 11x17 Art Preparation Pre-Press $1.84 *Average amount of screens coated is: 30 screens (Size: 20x24) per quart Supplies Cost: color or screen Item Cost Inks (Standard) $0.08 $20 /quart Inks (Poly Colors) $0.14 $25 /quart Inks (Glitter/Metallic) $0.16 $30 /quart Time /Labor Production $0.08 *Labor can be calculated on how many shirts /per hour in production. (Average: 50-60 pcs/ per hr.) Supplies Cost: color or screen Item Cost Ink Removal BIO1 $0.25 $44 /gal Emulsion Removal-ER-5 $0.15 $20 /gal Brushes $0.02 $3.50 /each Time/Labor Post Production $0.40 *Labor can be calculated on how many screens can be cleaned per hour. (Average: 10 screen per hr.)