The document discusses flat bed and rotary screen printing methods, highlighting the transition from semi-continuous to continuous processes, which enhances productivity and quality. Rotary screen printing allows for multiple colors and high-speed production, while screen printing offers versatility, durability, vibrant colors, and cost-effectiveness. It also mentions potential defects that can occur during the screen printing process.
The document discusses flat bed and rotary screen printing methods, highlighting the transition from semi-continuous to continuous processes, which enhances productivity and quality. Rotary screen printing allows for multiple colors and high-speed production, while screen printing offers versatility, durability, vibrant colors, and cost-effectiveness. It also mentions potential defects that can occur during the screen printing process.
The document discusses flat bed and rotary screen printing methods, highlighting the transition from semi-continuous to continuous processes, which enhances productivity and quality. Rotary screen printing allows for multiple colors and high-speed production, while screen printing offers versatility, durability, vibrant colors, and cost-effectiveness. It also mentions potential defects that can occur during the screen printing process.
The document discusses flat bed and rotary screen printing methods, highlighting the transition from semi-continuous to continuous processes, which enhances productivity and quality. Rotary screen printing allows for multiple colors and high-speed production, while screen printing offers versatility, durability, vibrant colors, and cost-effectiveness. It also mentions potential defects that can occur during the screen printing process.
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Flat Bed Screen Printing
A semi-continuous method of printing in which a
perforated flat screen is used to apply color. Designs are limited by the width and length dimensions of the screen and only one color per screen is allowed. Flat bed to Rotary screen: • Modification of flat bed screen printing: from semi continuous to continuous, low productivity to high productivity. • Quality of end result. • Evenness of color. • Ability to produce fine lines . • More compact than flat screen machines for the same number of colors in the pattern
• Rotary screen machines are highly productive, allow for the
quick changeover of patterns, have few design limitations, and can be used for both continuous and discontinuous patterns • Typical speeds are from 50-120 ypm (45-100 mpm) • High investment cost and the machines are generally not profitable for short yardages of widely varying patterns. • Controls approximately 65% of the printed fabric market worldwide. Rotary Screen Printing • Rotary screen printing is a continuous method of printing in which a perforated cylindrical screen applies a colorant made from either pigment or dye. The colorant is forced from the interior of the cylindrical screen and onto the fabric. A special pump automatically feeds a paste inside the perforated cylinder (or spherical screen) and, as the screen rotates, a squeegee device inside the screen pushes the dye through the screen onto the fabric. Each screen is independently driven and up to 16-24 separate colors can be applied. • The rotary cylindrical screens are set in place on the rotary printer. Screens are made from nickel and have a special coating that is burned out through a laser engraving process to make the design. • An aluminum ring on each end of the screen holds the screen in place onto the printer. The end ring should hold screens because the screens are very delicate and can easily be ruined. • A magnet bar and squeegee are inserted inside each individual cylindrical screen. These devices act as controls for the printing process and can be readjusted if the print needs more or less pressure in certain areas. • Magnet Bars (also known as color bars) are metal bars that react to the magnet underneath the belt (also known as a print blanket). • Just as there are large brushes and small brushes for painting, there are large and small magnet bars for rotary screen printing. The large magnet bars are used for blotch prints and the smaller bars are used for fine details. • A squeegee runs along the magnet bar and puts constant pressure on the screen, which pushes the colorant through the screen and onto the fabric. In order to prevent color contamination, the belt is constantly cleaned by a brush and water at the bottom of the printer. • Pigments or dyes are mixed in buckets and placed beside the printer at their color stations.
• The colorant is pumped into each printhead
separately.
• A sensor automatically registers whether the
printer needs more ink, thus the printer never stops. • When the print run is finished, the magnet bar and squeegee are removed, along with the screen.
• All parts of the printer are thoroughly cleaned
for future use. ROTARY SCREEN PRINTING Benefits Of Screen Printing
When considering using screen printing technology, there are many
benefits from which Some of the benefits are mentioned below:
• VERSATILITY • One of the main advantages of screen printing is its versatility. It can be used on any type of fabrics and multiple colors can be used. There is almost endless design freedom when using screen printing. • DURABILITY • Compared to other printing methods, screen printing can apply a heavy print coverage, resulting in a durable design. Additionally, certain coatings and additives can make the ink resistant to UV rays, scratches, moisture and chemicals, allowing screen-printed products to be used outdoors and in harsh environments without fading. • VIBRANCY OF INK COLOURS • The vibrant and bolder colors produced by screen printing is quite tricky to replicate with other techniques. For multiple color designs, separate layers are used, which allows each color to preserve its actual brilliance. • COST-EFFECTIVE • Screen printing is a cost-effective method in the long run. Once the set-up is done, printing items at high volumes is relatively quick and easy. So, it's safe to say the more you print, the cheaper the unit cost becomes. • EXCEPTIONAL SPEED AND EFFICIENCY • Screen printing is one of the most efficient and fast printing techniques once a screen has been created. It is an excellent option if the same design is to be printed over and over again. • STRAIGHTFORWARD PROCESS • The screen printing process is fairly straightforward, whether it is automated or done manually. Moreover, the required tools are also not hard or costly to replace. Defects on screen printing: • Out of registration – pattern out of fit. • Glue streaks – from the rubber blanket. • Color smear. • Color out – from a lack of print paste. • Creased fabric. • Pinholes in any screen. • Damage to the screen leading to misprints. • Lint on the fabric causes pick-off. • The prints may come out lighter in the middle and deeper towards the selvedges.
