How to Print Using a Puff Additive

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Screen printing offers a variety of ways to add dimension and texture to your designs, and one of the most popular methods is using a puff additive. This special ink additive expands when heated, creating a raised, three-dimensional effect that adds a unique touch to garments and other printed materials. If you’re looking to enhance your screen prints with a puff additive, follow these steps for the best results.

What You’ll Need:

  • Puff additive

  • Plastisol or water-based ink (Ensure you have the appropriate Puff Additive, as different types are required for Plastisol and Water-based inks)

  • Screen printing press
  • Properly prepared screen (typically mesh count between 34T/(80) to 90T/(230)
  • Squeegee
  • Heat source (flash dryer/conveyor dryer)
  • Garment or material to be printed on

Step-by-Step Guide to Printing with Puff Additive

Step 1: Mix the Puff Additive with Ink

Puff additives can typically be mixed with either plastisol or water-based ink although you will need the right one to match your ink. If you are using plastisol then you will need an additive specific to plastisol, same for waterbased. The recommended ratio varies by brand, but a common guideline is to use 10-20% puff additive per volume of ink. Thoroughly mix the additive into the ink to ensure even puffing.

Step 2: Prepare the Screen

Since puff ink is thicker than regular ink, use a lower mesh count screen (34T/80 to 90T/230) to allow for better ink passage. A higher mesh count may restrict the ink flow and lead to poor puff effects.

Step 3: Print the Design

Load your garment onto the platen and apply the ink using a squeegee with medium pressure.

Step 4: Flash Cure if Needed

If you’re printing multiple layers or colours, flash cure between layers to prevent smudging, until touch dry. However, Its important to avoid overheating, as premature puffing may occur.

Step 5: Cure with Proper Heat

To activate the puff effect, the print must be cured at the correct temperature. Most puff additives activate at around 140 -160°c. Use a conveyor dryer to achieve consistent results. As the ink reaches the right temperature, it will begin to expand and create the desired raised texture.

Step 6: Inspect and Test

After curing, check the design for even puffing and adhesion. Conduct a wash test to ensure durability. If the puff effect isn’t as pronounced as desired, consider adjusting the ink-to-additive ratio or curing temperature.

Printed using 15% Puff Additive ^

Pro Tips for Best Results

  • Experiment with ratios: Different amounts of puff additive will create varying levels of puffiness. Test small batches to find the right mix for your project.
  • Use bold designs: Fine details may not translate well with puff printing, as the ink expands and can blur small elements.
  • Store ink properly: Puff additive inks can thicken over time, so store them in a sealed container and mix well before each use.

Final Thoughts

Printing with a puff additive is a great way to add texture and a dynamic look to your designs. With the right materials, technique, and a bit of experimentation, you can create eye-catching prints that stand out. Whether for fashion, branding, or artistic projects, puff ink provides an easy and effective way to elevate your screen printing game.

Give it a try and see how puff printing can bring a new dimension to your designs!

 

Our Amex Waterbased Puff Additive 

Our Amex Plastisol Puff Additive

 

Need some help? Call us on 01562 829009, email us info@screenprintworld.co.uk or use our online live chat function!

Go Green with the Sgreen® Filtration System: A Cleaner Solution for Screen Cleaning

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In the world of screen printing, maintaining an eco-friendly shop can be challenging, especially during the screen cleaning and reclaiming process. Even when using environmentally friendly inks and chemicals, harmful waste solids can still end up being flushed down the drain, potentially harming plumbing systems and the environment. That’s where the Sgreen® Filtration System steps in to make a difference.

Protect Your Plumbing and the Planet

The Sgreen® Filtration System is an advanced ink filtration solution designed to remove harmful waste solids from your screen cleaning process. By placing this system under your washout booth, you can ensure that waste products are filtered from the water before it flows into your plumbing, creating a greener and more sustainable shop environment. With the Sgreen® Filtration System, you can work confidently, knowing you’re reducing your ecological footprint.

Six Stages of Superior Filtration

What sets the Sgreen® Filtration System apart is its comprehensive six-stage filtration process, which ensures optimal water cleanliness:

  1. Disposable Filter: The first stage captures larger particles immediately, preventing them from clogging the system.
  2. Reusable Mesh Screens: The water then passes through a series of three reusable screens with mesh sizes of 86, 156, and 200, progressively filtering finer particles.
  3. Pump Holding Tank: After the initial filtration, the water collects in a holding tank equipped with a high-powered industrial sump pump.
  4. Final Filters: The pump pushes the water through two final stages—a 70-micron filter and a 20-micron filter—removing any remaining particulates.

By the end of this rigorous process, most solids are removed, and any residual particles are reduced to a size as small as 20 microns. This ensures you’re left with clean, filtered water ready to be safely discharged.

Seamless Integration and Easy Maintenance

The Sgreen® Filtration System is designed for convenience and efficiency. It fits snugly underneath the Sgreen Wash Booth, keeping your workspace organized while providing easy access for cleaning and changing filters. The system’s reusable screens and durable construction ensure long-term performance and cost savings.

A Step Toward a Greener Future

Adopting the Sgreen® Filtration System is more than just an investment in your screen printing shop; it’s a commitment to sustainable practices. By filtering harmful waste solids from your water, you’re protecting not only your plumbing but also the environment. With the Sgreen® Filtration System, you can take pride in running a cleaner, greener, and more responsible business.

Ready to Make the Switch?

Take the next step in eco-friendly screen printing. Upgrade your shop with the Sgreen® Filtration System and enjoy the benefits of a cleaner workspace and a cleaner conscience. It’s time to protect your plumbing, your business, and the planet, all with one powerful solution.

 

 

Have any questions? Give us a call on 01562 829009, email us at nick@screenprintworld.co.uk or use our Live chat function!

Find out more:

Sgreen Washout Booth Filtration System

 

 

Screen Printing vs. DTF: Why Screen Printing Takes the Lead

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In the world of custom apparel and textile decoration, two popular methods have emerged as front-runners: screen printing and Direct-to-Film (DTF) printing. While both techniques offer unique benefits, screen printing continues to hold its ground as the superior choice for many applications. Here’s a closer look at both methods and why screen printing deserves the spotlight.

What Is Screen Printing?

Screen printing is a traditional method where ink is pushed through a stencil (or screen) onto the fabric. This technique has been around for decades and is prized for its durability, vibrancy, and cost-effectiveness for large orders.

What Is DTF Printing?

Direct-to-Film (DTF) printing is a newer method where designs are printed onto a special film, which is then heat-pressed onto fabric. This technology has gained traction for its ability to produce detailed, full-color designs with minimal setup.

The Advantages of Screen Printing

1. Durability and Longevity

Screen printing inks bond deeply with fabric, creating a finish that withstands frequent washing and heavy wear. This makes it the preferred method for apparel that needs to last, such as uniforms, team jerseys, or promotional items.

In contrast, DTF prints are prone to cracking or peeling over time, especially with regular use and washing. Screen printing ensures a lasting impression, literally and figuratively.

2. Vivid and Consistent Colors

Screen printing excels in delivering vibrant and opaque colours, even on dark fabrics. With the ability to layer thick, high-quality inks, screen printing achieves a richness and uniformity that DTF struggles to replicate.

DTF prints can sometimes appear muted or inconsistent, particularly on textured or dark materials.

3. Cost-Effectiveness for Bulk Orders

Screen printing becomes increasingly economical as order quantities rise. Once the screens are set up, the production process is fast and efficient, making it ideal for bulk orders.

While DTF printing shines in small-scale or one-off projects, it becomes less cost-effective for larger runs due to slower production speeds and higher material costs.

4. Versatility Across Fabrics

Screen printing works beautifully on a wide range of fabrics, including cotton, polyester, and blends. Specialized inks, such as water-based or discharge inks, add even more versatility to this method.

DTF printing, while compatible with various fabrics, may not achieve the same level of adhesion and quality across all materials.

Limitations of DTF Printing

  1. Durability Concerns: As mentioned earlier, DTF prints are more susceptible to wear and tear, diminishing their appeal for high-usage items.
  2. Environmental Considerations: DTF often involves using more plastic-based materials, including PET films, which raises sustainability concerns. Screen printing, particularly with water-based inks, can be a more eco-friendly choice.
  3. Setup Time vs. Quality: While DTF printing offers quick setup times, the trade-off often comes in the form of lower-quality finishes, especially for large designs or intricate details.

Why Screen Printing Stands the Test of Time

Despite the rise of newer technologies like DTF, screen printing remains the gold standard for high-quality, durable, and visually striking prints. Its ability to produce consistent results across large orders, coupled with its proven longevity, makes it the go-to method for businesses and creators alike.

While DTF has its place for small-scale or highly detailed projects, the enduring reliability and vibrancy of screen printing ensure it’s here to stay. For those looking to make a lasting impression, screen printing is the undeniable champion.

How to Save Labour Costs in Screen Printing: Top Tips and Must-Have Machinery

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Running a screen printing business comes with unique challenges, and one of the most significant expenses is labour. Whether you’re just starting out or looking to refine your operations, finding ways to reduce labour costs without sacrificing quality is essential for growth and profitability.

In this blog post, we’ll explore practical strategies to streamline your production process, reduce manual effort, and maximize efficiency. From adopting innovative machinery to implementing smart workflow practices, we’ll share actionable tips and recommend equipment that can save you time, energy, and money.

Whether you’re looking to increase output, reduce waste, or simply make your team’s workday smoother, this guide will equip you with the knowledge to stay competitive in the dynamic world of screen printing. Let’s dive in and discover how to do more with less!

 

1. Optimize Your Workflow

    • Streamline your production floor layout to reduce unnecessary movement.
    • Implement a clear, step-by-step process for every task, from screen preparation to final packaging.
    • Train employees to multitask efficiently without sacrificing attention to detail

 

 2. Invest in Automation
Manual tasks like screen cleaning, alignment, and repetitive printing can be automated to save time and labour. Automation also ensures consistency, reducing errors and waste.

 

3. Schedule Smartly

    • Prioritize jobs based on complexity and deadlines to minimize downtime.
    • Use job batching to group similar designs or colours together for faster processing.

 

Machinery that can help save on labour costs: 

 

The D2M Screen maker

The D2M eliminates the need for exposure and washout processes. It only requires one person to input the artwork and monitor the machine as it prints your design directly onto the mesh, ready for immediate use.

The M&R Password Auto Take Off System 

An automatic textile unloader for automatic screen printing presses. It will grab your garment directly for your press and transfer it to your dryer, Removing the need for a person to unload garments manually

The M&R Turnabout Ink Mixer

Mixing alot of pantones? The M&R Turnabout ink mixer efficiently handles ink mixing, freeing up workers to focus on other tasks.

Manual and automatic squeegee cleaners 

Save time and money with automatic and manual squeegee cleaners.

M&R’s Qwik-Klean™ automates the highly labor-intensive, tedious process of cleaning squeegee holders and floodbars – This machine can clean up to 24 squeegees at a time.

The Manual Squeegee Cleaner will make cleaning your manual or automatic squeegees easier than ever if you have a smaller set up. Simply insert the squeegee between the brushes and slowly turn the handle. The scrubbing action of the quad-brush formation will clean the dirtiest squeegees in seconds

The Autoglide 4060 Heat Press 

The Autoglide heatpress has double tables side by side for enhanced productivity: while pressing on one base plate, place the next garment to be personalized on the other,  improving efficiency and production levels.

M&R Automatic Screen Cleaners 

M&R offers a range of automatic screen cleaners designed to streamline your screen room operations. Simply load your screen, and the machine takes care of cleaning and reclaiming your screens for you – again, freeing up workers to focus on other tasks.

 

Reducing labour costs in screen printing isn’t just about saving money—it’s about building a smarter, more efficient operation. By optimizing your workflow, investing in time-saving machinery, and embracing automation where possible, you can improve productivity, reduce errors, and free up your team for more value-driven tasks.

Whether you’re upgrading to an automatic screen printing press, using pre-registration systems, or streamlining processes with effective training and tools, every step you take toward efficiency pays off in the long run. Lower labour costs mean higher profitability, faster turnaround times, and the ability to scale your business with confidence.

Implementing these tips and investing in the right equipment is a surefire way to stay competitive in the ever-evolving screen printing industry. Start making these changes today and watch as your business grows stronger, leaner, and more profitable!

 

 

 

A guide to: Booking and sending your remesh screens

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One of the questions we get asked the most is, “How does your remeshing service work?” To make things easier, we’ve put together a helpful guide that explains the entire process from start to finish.

But before we get into that, lets look at why its a good idea to remesh your old screens..

Remeshing your screens is essential for several reasons:

  1. Maintaining Print Quality: Over time, the mesh on screens can become stretched, damaged, or clogged with ink, leading to inconsistent or poor-quality prints. Remeshing ensures a smooth, even surface for precise and sharp designs.
  2. Prolonging Screen Life: Instead of replacing the entire frame, remeshing allows you to extend the life of your existing screens. This is cost-effective and reduces waste.
  3. Ensuring Ink Flow: Properly tensioned and clean mesh allows ink to pass through evenly, ensuring consistent ink deposits, which is critical for vibrant, high-quality prints.
  4. Adapting to Design Needs: Different designs and inks require different mesh counts. If you don’t have space for lots of different mesh sizes, then remeshing allows you to switch to a suitable mesh count for the specific project, ensuring the best possible results.

How to guide for booking and sending your screen back to Screen Print World for remeshing

 

Have any questions? Email our remeshing department – Jamie@screenprintworld.co.uk or our customer service team – info@screenprintworld.co.uk

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.

 

 

A Beginner’s Guide to Exposing a Screen 

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A Beginner’s Guide to Exposing a Screen

If you’re new to screen printing, one of the most crucial steps you’ll need to master is exposing your screen. This process involves transferring your design onto the screen so you can use it to print on various materials like t-shirt’s, hoodies and posters. Let’s dive into the step-by-step process to ensure you get a crisp, clear image every time.

What You’ll Need

Before you start, gather the following materials:

  • Screen printing frame and mesh: Pre-stretched screens are available in different mesh counts. Choose one suitable for your design detail and ink type.
  • Emulsion: A light-sensitive liquid that coats your screen.
  • Emulsion coater: Used to apply emulsion evenly across the screen.
  • Design transparency: A high-contrast black and white image printed on a transparent film.
  • Exposure unit or light source: UV light is most effective for exposing screens.
  • Exposure Calculator: To find the correct exposure times
  • Emulsion remover: For cleaning the screen if you make a mistake.
  • Dark room or low-light area: To apply and dry the emulsion without exposing it to light
  • A block out solution/pen: to touch up any pin holes

Step-by-Step Guide

  1. Prepare Your Screen and Workspace
    • Ensure your screen is clean and free of any dust or debris. We recommend cleaning with a degreaser and drying prior to coating.  A clean workspace is essential to avoid any unwanted particles getting stuck in the emulsion.
    • Work in a dark room or low-light environment to prevent premature exposure of the emulsion.
  2. Coat the Screen with Emulsion
    • Pour a small amount of emulsion into your emulsion coater
    • Starting from the bottom, Tilt your emulsion coater onto your screen so the emulsion is touching the mesh. Pull your emulsion coater up gently, making sure you don’t loose contact. When at the top, tilt back and pull away from the screen.  Repeat on the other side. Note: A thin, even coat is essential for a successful exposure.
    • Allow the screen to dry in a dark place. A drying cabinet or drying rack is an ideal place to dry screens but if you don’t have access to one you can dry in a dark cupboard.  This may take several hours, so patience is key.  Make sure you dry your screen so the print side (where you put the ink) is facing upwards. This ensures any drips that form stay on he other side of the screen and do not create an un-even texture on the print side.
  3. Position Your Design Transparency
    • Once the emulsion is dry, place your design transparency on the screen. The side with the ink should face the screen to ensure sharp detail transfer.
    • Secure the transparency in place with tape if necessary.
  4. Expose the Screen
    • Place the screen on the exposure unit or under your light source. Ensure even contact between the transparency and the screen to avoid blurred lines.
    • Exposure time will vary depending on your light source and emulsion type. Consult your emulsion’s instructions for guidance, but typically it ranges from 1-10 minutes. We highly recommend a exposure calculator to dial in your exposure times. This can cut the experiment stage in half and put a stop to any guessing games when it comes to troubleshooting
  5. Rinse the Screen
    • After exposure, rinse the screen with water to wash away the unexposed emulsion. Use a gentle spray and gradually increase the pressure if needed.
    • The exposed areas (where the light hit) will harden, while the unexposed areas (your design) will wash away, creating a stencil.
  6. Dry the Screen
    • Allow the screen to dry completely before using it for printing. Ensure it’s stored in a dust-free environment.
  7. Inspect Your Screen
    • Hold the screen up to the light to ensure all design areas washed out correctly. If there are any imperfections, you can use emulsion remover to clean and start again. You can also use a block out solution/pen to touch up any pin holes to save re-doing the process completely.

Tips for Success

  • Test Exposure Time: Conduct a step test using an exposure calculator to dial in correct exposure times
  • Emulsion Storage: Store your emulsion in a cool, dark place to extend its shelf life once mixed
  • Transparency Quality: Use high-quality transparency films and inks to ensure sharp and clear design transfer.

Troubleshooting Common Issues

  • Underexposure: If your design washes out entirely, increase your exposure time.
  • Overexposure: If no part of your design washes out, reduce the exposure time or check for light leaks during the coating process.
  • Uneven Emulsion: Ensure you’re applying a smooth, even coat of emulsion. Practice makes perfect.

Exposing a screen for screen printing may seem daunting at first, but with practice and attention to detail, you’ll be able to create crisp, professional-quality prints.

 

Introducing Print Grip

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Introducing PrintGrip: The revolutionary platen adhesive pad

Say goodbye to single-use adhesives and hello to PrintGrip, the innovative way to keep your garments in place. PrintGrip is a 1mm polymer gel pad that offers a clean, reusable, and more effective alternative to traditional pallet adhesives. With a lifespan of 4-6 months per pad, switching to PrintGrip can save you hundreds of pounds on adhesive and cleaning.

PrintGrip boasts superior adhesive properties, significantly reducing the need for spray and pallet glues. This not only makes your printing process more efficient but also more eco-friendly. Its exceptional adaptability makes it suitable for a wide range of fabrics, including 100% cotton, 50/50 cotton/poly blends, 100% polyester, light to medium weight fleece, and even tri-blends.

For printers seeking reliable adhesion across various materials, PrintGrip is an indispensable tool. Whether you’re handling small print runs or large-scale projects, the PrintGrip High Tack Yellow Sheet ensures impeccable results with every print.

Not only does PrintGrip save you money, It also also great for protecting your platens and extending there lifespan. No more scrubbing away stubborn adhesive, pallet mask and residue, Once you have finished using your Print Grip Pad, simply peel off and reapply.

Shop Print Grip

 

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Introducing the D2M Rapid Screen Stencil Making Machine + Q&A!

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