Impressions - June/July 2016 - 28

SCREENPRINTING

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very printer addresses the numerous
variables in the screen-priting process
differently. Thus, when a decorated
apparel facility finds a procedure that works
perfectly, the staff should document and
standardize it to achieve consistent results
between runs.
While the real secret is to put effort into
research and development to identify what
will work in your facility, the following five
procedures have been identified, implemented and standardized by some printers to
streamline processes or improve the quality
of finished products.

From printing with
plastisol to controlling
ink viscosity, every
printer should
know these five
production secrets.
By Rick Davis,
Contributing Writer

1. Smoothing Plastisol Prints
Some clients complain about a print's rough
surface, which typically results from uncontrolled variables in the process. Many printers
use a heat press to smooth out the surface
and soften the hand on finished garments.
Most printers use a Teflon sheet, which
comes with many heat-press kits. The issue is that the Teflon sheet used in the heat
stamping/smoothing process results in a glossy
finish, giving the finished print a high-gloss
appearance similar to that of a heat transfer.
The Secret: Instead of using a Teflon sheet,
try parchment paper, which will have the same
smoothing effect, except the print will be
completely flat with no gloss.
2. Minimizing Puff Puckering
Puff inks are making a strong comeback in

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I M P R E S S I O N S M A G . C O M JUNE/JULY 2016

Above

"The Inkubator" is
a crate developed by a
Minnesota screen-printing
facility to keep inks warm
in cold climates at night.

the textile screen-printing industry. The primary issue that plagues screen printers using
this ink type is puckering.
When printing large image areas, the ink
puffs during the curing process and its expansion against the fabric results in the ink film
or fabric contorting into an uneven surface.
The Secret: Break up the image to minimize
the puckering effect. A common strategy is
to use halftone patterns, which is the right
idea, but when the ink film expands, it also
reproduces the halftone pattern in the ink-film
surface. The repetitive pattern is more than
obvious. You need a non-repetitive pattern,
which will allow the ink film to properly expand and make an even, solid ink film while
minimizing the puckering effects of the solid
image areas.
It is best to select a 75%-80% solid/nonrepetitive pattern for larger image areas. This
will break up the 100% solid underbase to
minimize the puckering effect. The 70%-80%
solid ink film will then mushroom during
expansion to create the 100% solid surface.
3. Discharge Underbasing
Although discharge underbasing is neither
new nor a secret, many printers still want a
softer hand after using the application. Numerous printers who have avoided the process
have inquired about it, as they have never
printed with water-based ink, let alone with
a discharge application.
Although printing through standard fine

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Impressions - June/July 2016

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