Impressions - May 2020 - 50

its DTG machines with great success for operators.Wet-on-wet
printing requires a long dwell time in a big conveyor dryer; if
space is a concern, these big printers and dryers can be a setback.
For DTG printers that don't have built-in pretreatment functions,
there are several equipment manufacturers working on pretreatment
automation - a standalone unit that pretreats, cures and presses a
shirt so that it's ready for DTG decoration. Currently, pretreatment
automation also commands a lot of space and investment; for
most small to mid-tier operators, this may not be a viable option.
If your shop can't automate pretreatment, consider a reliable,
fast, standalone machine to perform this function.This may seem
counterintuitive, but with proper production techniques, it can
be extremely efficient. For example, on any DTG printer except
Kornit,pretreatment solution must be dry before printing.However,
in many cases, there are few rules on how drying should be done.A
pretreatment machine set up next to a forced-air conveyor dryer
can produce more than 120 cured shirts per hour, even without
the need for a heat press. It's all in your technique.
Color & Consistency
Color gamut and special effects are another area where screen
printing has the upper hand, but this is an issue that also is being
addressed by industry manufacturers.Companies like Kornit Digital
are increasing their color gamut to include more fluorescent and
brighter colors. Epson's CMYK printer has a vibrant color range
and M&R is adding colors and special-effects options. Manufacturers know decorators want all the bells, whistles and color options.
The future will allow for easier application of foils, metallic and
other special-effects inks.
Consistency is essential for productivity, and this is where DTG
advancements likely will outperform screen printing, which has
several variables that can throw off continuous, consistent production. Running out of ink, broken screens, inaccurate registration,
ink buildup on the bottom of screens, shirt shift and stretching,
flash-unit issues, etc., are all problems that hamper consistency.
Screen printing can be a sensitive process. Digital printing,

Manufacturers are working on
pretreatment automation -
a standalone unit that pretreats,
cures and presses a shirt so that
it's ready for DTG decoration.

P.50

however, can significantly reduce a lot of those manual issues via
automation and technology.We already are seeing developments
with bulk-ink systems, sensors that adjust platen height, internal
cleaning automation and more.With these advancements, DTG
decorators are nearing 100% confidence that the shirt they load
will be perfectly printed and ready for sale. Confidence in perfect
production is the consistency that is needed, and digital decorating
promises to continue to deliver on that need.
The rapid advancement of DTG printers is quickly demonstrating how technology will only continue to allow us to deliver
exactly what customers wants in a reliable, efficient, and more
consistent and profitable way. 
John LeDrew is the DTG director for Melco Intl. He has worked professionally in
garment decoration since 2006, managing accounts and overseeing production
for some of the world's largest brands and retailers. For more information or to
comment on this article, contact John via LinkedIn.

THE CURING QUESTION
Another DTG-printing bottleneck involves curing a wet, printed
shirt. Many operators think a heat press is required, which is false.
Part of the reason screen printing is so efficient - once it is set
up - is because the embellished shirt gets pulled off the press and
dumped on a conveyor belt to cure. Wet DTG prints also can be
cured in the same manner.
Historically, the drawback of curing DTG prints with a conveyor
dryer has been the size requirements for a functional forced-air
dryer, which is required for properly curing water-based DTG ink.
Until recently, dryers were a minimum of 36" x 12'. New technology
has condensed these dimensions dramatically. For example, BBC
Industries Inc. has released a 24" x 8' forced-air dryer that cures wet
pretreated and printed shirts in about two minutes.

Manufacturers
constantly are
developing new
technology to increase
DTG-printing speed.
In the future, expect
speeds in conjunction
with reliability to be
more commonplace.

I M P R E S S I O N S M A G . C O M MAY 2020

48-50_IMP_0520_TMD_DTG.indd 50

4/15/20 6:29 PM

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Impressions - May 2020

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