Common Exposing Problems And Solutions

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In this blog, we’ll explore the most common exposing problems in screen printing, understand their causes, and provide practical solutions to help you achieve consistent, high-quality results. Whether you’re troubleshooting existing issues or looking to refine your process, this guide will be your go-to resource for overcoming screen printing challenges.

 

Emulsion Washing out completely 

If your emulsion if washing out completely or partly then your screen might not be exposed enough, Meaning you need to up your exposure times. To dial in your exposure time and save yourself a lot of hassle, We recommend purchasing an exposure calculator. You can use this to establish the correct amount of time you need to expose your screen, Without the need to keep creating and exposing new screens.

Another common problem is not adding the sensitizer. Check your emulsion as some come pre-sensitized and some come with a separate sensitizer which needs to be mixed to activate your emulsion. Don’t forget to label with the date you mixed your emulsion, Most emulsions come with a 6 month life once mixed – If your emulsion is older than this, That might be why it is washing out.

 

Emulsion not washing out at all

Your screen is most likely over exposed. Too much light exposure can over-harden emulsion, Preventing it from washing out and revealing your design. We recommend the same as above. Use an exposure calculator to establish the correct time. Always check the emulsion you are using and that you have prepared according to instructions.

 

Taking too long to expose

If your emulsion is taking too long to expose, We suggest

1) check the emulsion you are using. Some emulsions take longer to expose compared to others. If you want to up your exposure times, find an emulsion suitable for this.

2) Your exposure bulbs may need changing. Depending on how long you have had your exposure unit, bulbs will deteriorate over time with daily use. If they are not working at full capacity, then your screen will take longer to expose.

 

Pin holes or flaking emulsion

Sometimes your screens can get pin holes or your emulsion can even flake off, this can be down to not de-greasing your screen. Always de-grease your screen, even if they are brand new. This will remove any invisible residue from production or previous print runs. It allows a good adhesion between emulsion and screen.

 

Your design edges aren’t crisp enough 

If you are finding your design isn’t crisp enough, There are two things you should make sure of:

1) That your positive isn’t dark enough. You’ll need to use a high quality black ink and printer to get dark positives. If your design isn’t dark enough, It will let light through during the exposing process.

2) You don’t have good connection between glass and positive. If you have a vacuum exposure unit, Then check that you are getting good suction, If not then check for holes in your exposure blanket that could be letting air in. It may be that repairing or replacing the blanket can improve your screen exposure.  If you are using a standard exposure unit, You can add a piece of foam in the well of the screen to create good contact.

 

We know sometimes exposing screens can be a mindfield, However following this simple steps should help you streamline your exposure processes. If you have any other exposing questions, please get in touch via email, webchat or phone (01562 829009) and one of your team can assist you.

 

 

 

 

 

Our top tips for streamlining your printshop

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Running a print shop is a creative and rewarding endeavour, but it also comes with its fair share of challenges. From managing production schedules to ensuring high-quality output, efficiency is key. One of the most effective ways to streamline operations in your print shop is by investing in the right tools that can enhance workflow, reduce downtime, and improve the overall quality of your prints. here are some top tips that can significantly improve your print shop’s efficiency

1. Invest in a Dip Tank

Cleaning screens is one of the most time-consuming tasks in a print shop, but it’s also one of the most crucial. A dip tank is an essential tool that can streamline this process, making it faster and more efficient. Dip tanks allow you to submerge screens in a cleaning solution, breaking down ink and emulsion residue more effectively than manual scrubbing alone.

Benefits of Using Dip Tanks:

  • Time Efficiency: Dip tanks automate a significant part of the cleaning process, allowing your team to focus on other tasks while screens are being cleaned.
  • Improved Cleaning: The consistent exposure to the cleaning solution ensures that all ink and emulsion are thoroughly removed, leading to cleaner screens and better print quality.
  • Cost-Effective: By reducing the need for excessive scrubbing and chemical use, dip tanks can help lower your operational costs in the long run. You can also save up tp 60% on chemistry costs

2.  Squeegee Cleaners are your print shop friend

Squeegees are the workhorses of any print shop. Over time, ink buildup can cause squeegees to lose their effectiveness, leading to poor print quality and increased waste. Manual squeegee cleaners are a simple yet powerful tool to maintain the durability and performance of your squeegees. Simply glide your squeegee through the table top squeegee cleaner and turn the handle to clean your squeegee. All you need is a little cleaning fluid in the machine and you are good to go.

Advantages of Squeegee Cleaners:

  • Consistent Results: Regular cleaning ensures that squeegees maintain their edge, providing consistent ink distribution across the screen.
  • Extended Squeegee Life: By keeping squeegees clean, you reduce wear and tear, which can prolong their lifespan and save money on replacements.
  • Ease of Use: Manual squeegee cleaners are straightforward to use, making them an accessible tool for any member of your team.

3. Reduce your set up time with PrintGrip

When it comes to handling garments, precision and stability are crucial to achieving high-quality prints. PrintGrip is a tool designed to securely hold garments in place during the printing process, ensuring that they don’t shift or move, which can lead to misaligned prints. Most printshops use spray or waterbased glue, Which is usually applied before a printjob to maintain optimal tackiness though-out the printing day. Unlike PrintGrip, Which stays tacky for 3-6 months. Simply apply the pad to your platen and clean lint build up regularly with cleaning fluid.

Why PrintGrip is a Must-Have:

  • Improved Accuracy: By keeping garments stable, PrintGrip minimizes the risk of errors, resulting in sharper, more precise prints.
  • Increased Efficiency: With PrintGrip, you can set up screens more quickly, reducing downtime and allowing for faster production cycles.
  • Cost-efficent – You won’t need to keep buying adhesive, Just replace your sheets every 3-6 months depending on effectiveness.

 

By automating and streamlining essential tasks, these tools free up your team to focus on what they do best—producing high-quality prints. The initial investment in these tools will quickly pay off as you see reduced downtime, lower waste, and a more efficient production process.