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Posts Tagged ‘printing technology’

Learn FM Screening to get Moire Free Prints & Achieve Digital Like Quality by Screen Printing

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In all my future workshops at DMI on textile screen printing you can now learn in depth about high definition screen printing process using 2nd Generation FM Screening technique to print DIGITAL like quality by SCREEN PRINTING process.

DMI is the first and only institute in the WORLD teaching latest and advance screen printing process in graphics and textile field and demonstrating the state of art high definition screen printing on textile using 2nd generation FM screening live and practical for free.

DMI is the only institute in the world teaching, graphics, industrial, print finishing, value addition and textile screen printing for free under one roof.

In all my workshops I teach right from designing to pre-press to colour management to screen making, screen printing, post-press live and practical all three days.

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Left Side Image (AM Screening) – Right Side Image (2nd Generation FM Screening)

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On 5th June 2015 during our grand re-opening of DMI institute in our new premises. I had made a statement in front of 100’s of printers who were present there, that “Once upon a time there was a moire problem in screen printing… what I meant was that moire will be a history in screen printing industry from now onwards. Yes at DMI we successfully implemented it and have also started conducting workshops and training programs on this subject.

So, MOIRE is no more a problem in screen printing with 2nd Generation FM Screening Technique.

After years of research and development in screen printing at DMI I have completely discarded AM screening in all my courses. Now I am only focusing on 2nd Generation FM Screening techniques which produces digital like quality through traditional screen printing process in graphics and textiles.

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Moreover the advantage of using 2nd generation FM screening is to avoid moire in screen printing. Especially when printing halftones on garment it becomes very difficult to control moire even after using coarser halftone dots like 45 LPI.

2nd generation FM screening totally eliminates moire in screen printing thus delivers sharp, crispy and brighter images. Even finer and smaller details are clearly visible.

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Left Side Image (AM Screening) – Right Side Image (2nd Generation FM Screening)

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To take one step further in the implementation of the 2nd generation FM screening in your company. I have made some test files which you can download and print at your end to check and compare the results of 2nd Generation FM screening vs conventional AM screening.

Email to: dtg@graficaindia.com or call us on our helpline number +91 8 655 755 855 so that we can send you the link to download DMI’s complete “Step-By-Step Instruction Guide”. This guide also explains how to print 2nd generation FM Screening to produce digital like quality through screen printing process.

Along with the instruction guide I have included many TEST FILES in PDF Format ready for positive output on any imagesetter. So once you download the test files, you can again call us on our helpline number for further guidance.

At DMI, Learn More – Earn More and be innovative.

Bhargav Mistry

Helpline Number for Screen Printers

June 15, 2016 2 comments

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It gives me immense pleasure to announce that screen printers across the globe can now call on this special HELPLINE Number for any kind of technical support related to screen printing process.

 

+91 8 655 755 855

 

Timing : 12.00 pm ~ 1.00 pm and 4.00 pm ~ 5.00 pm (IST), Monday to Thursday

DMI’s technical team including me will try to solve your problems well within DMI’s scope.

As you know DMI is connected to many international experts in screen printing. So, if your problem is not solved within our scope, we will also try to get solutions from international experts associated with DMI.

I am sure this HELPLINE facility will enable screen printers to improve quality standards and resolve day to day problems.

Have a trouble free screen printing…

Bhargav Mistry

Attention Garment Screen Printers, Are you making profit or just surviving?

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I am writing this blog to educate all garment screen printers with regard to the factors which influences costing. And after going through these points one can correct themselves to avoid further loss in business.

It’s difficult to educate or inform everyone, on one to one. So I thought the best way is to write this blog so that everyone can read, understand and implement these points before quoting for your customers job.

As garment screen printers you should never forget that you are helping your customers to sell their printed garments and because of your quality and services they are able to sell their garments in the market effectively.

Majority of garment screen printers, mainly into job work, only consider ink cost and add ‘margins’ with an understanding that the so called ‘margin’ covers their direct and indirect costs. It’s surely a blind faith!

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I have been conducting workshop and seminars in my institute DMI since 2006. In this 10 successful year I have been teaching advance screen printing process on latest machine and equipments using high quality materials and consumables.

During my 3-day workshops, screen printers sincerely write down all the methods and processes that are explained in my theory and practical sessions, and they even take photographs, probably to implement in toto what I teach. But back in their print shop, they seem to be hesitating to use the same method, products or similar quality materials like inks, emulsions, screen mesh, squeegee rubber etc, just because they find it ‘expensive’ compare to what they currently use. And, the end result: they fail to emulate the kind of quality that we have demonstrated in the workshop.

Frankly, the materials are not that expensive but printers are compelled to use lower standard materials and consumables because of their wrong costing and pricing structure prevalent in the market.

Most of the screen printers in textile and garment sector, especially engaged in job work only considers INK as their major cost while making their price-list per colour basis but they totally forget so many important factors during their calculations before sending quotations to customers.

To begin with, for the time being keep the cost of ink, emulsion, screen mesh out from your mind for a while because if you are not taking into account the following things while quoting your customer than I am seriously concerned whether you are making profit or just surviving in your business?

  1. Designing
  2. Positives
  3. Screen making
  4. Rejections
  5. Ink wastage
  6. Squeegee rubber & its maintenance
  7. Electricity charges per piece
  8. Labour
  9. Overtime
  10. Plant & Machinery
  11. Machine maintenance / AM
  12. Spare parts for plant and machinery
  13. Administration & office expenses
  14. Sampling
  15. Other overheads etc…

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DESIGNING:

Even if you have your own art department and artists to do designing, that doesn’t mean it’s not costing you money. Whether the lot size is bigger or smaller, design charges should be added in the costing. Be cautious that if designing charges are not taken from customers as a matter of regular practice, then you as screen printers end up struggling to purchase high quality designs or hire professional designers. But if you start charging for designs, you will not hesitate to purchase high quality designs from professionals or other online paid source, and hire experienced / professional designers for your pre-press activities.

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POSITIVE:

Majority of screen printers in garment/textile sector use tracing paper (generally knowns as ‘butter’ paper) and output their positives on desktop laser printer. It’s because customers don’t pay so printers try to save on designing and positive making and finally struggle for getting good quality printing. Even I have noticed that inkjet films are also considered ‘costly’. Hence image setter positives are out of question.

So always charge to customer for designing as well as positive making especially for smaller lot size.

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SCREEN MAKING:

Screen is the heart of screen printing. I always mention in my workshops ‘Good Screens = Good Quality Prints’. Believe me screens plays the major role in the quality of printing and many screen printers don’t have any idea what should be the right quality of screens. Textile screen printers main focus is alway ‘automatic machine’. But I would like to remind printers once again that to achieve 100% QUALITY in garment screen printing,

Designing & Positives (Pre-press) has 40% role
Screen Making – 40%
Automatic Machine – 10%
Inks & Consumables – 10% Provided if you are using high quality materials and consumables from renowned companies

The reason why screen printers end up making poor quality screens is because they don’t charge their customers for screen making nor they add it in their pricing based on the lot size. Hence they are compelled to use substandard positives, screen mesh, emulsions, chemicals and unprofessional way to develop screens.

Screens are not FREE it cost you lot of money and also does not last longer so it should be charged to customers separately.

The life of screens for printing photographic images with water base inks using fine halftone dots last only upto 500 to 700 impression. If you are lucky or if you have not cleaned the screens in between production due to ink choking or during any intervals etc. than it can deliver upto or over 1000 impression.

POOR INK & EMULSION QUALITY reduces your screen life so use the best mesh, emulsions, chemicals and inks. The life of the screen especially in halftone printing majorly depends on ink so use high quality inks which reduces ink choking issues thus eliminates screen cleaning during production thus avoids stencil wear & tear.

The life of screen can sometimes double or even more with PVC free-phthalate free plastisol inks compare to conventional water based because these plastisol inks does not choke up in screens and does not require cleaning in intervals. But nowadays many companies makes very high quality low-choking water base inks which can also eliminate screen cleaning during production thus increases the life of the screens.

The screen making charges also depend on the number of colours and type of screen required for printing. E.g. the cost of high density screen should be charged higher compare to conventional screen making because it take more time with special attention and care plus the cost of thick film is also higher compare to conventional emulsions.

And don’t forget that screens do have limited life, sometimes it tears due to poor handling or during printing due to dust particles in ink. So in a month some amount of new screen mesh has to be considered in your costing.

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MACHINE SETUP:

Most of the job workers (garment printers) complain that their lot size has now shrunk between 300 and 500 pieces per lot.

So, in this case it would be the biggest blunder or loss making, if you are not charging or considering the cost of machine setup. Everyone knows ‘job changeover’ time is the biggest nightmare in garment printing.

According to me, on an average, the time taken by screen printers practically to change from one job to another is around 1 to 2 hours, or sometimes even more depending on number of colours and accuracy of the job.

If a company runs 8-hour shift (which never happens practically you know!) they end up with average 6.5 or 7 hours a shift. In that case average only 3.5 lots can be finished per shift, considering a min. order of 300 or max. 500 piece per hour considering 1 hour spent for job changeover and setup in between.

So, if you do not charge/consider ‘job changeover’ time and ‘machine setup’ time for smaller lots, then even survival would be difficult, forget about making profit. Because most of your ‘profits’ are being leaked out incognito due to time lost in job change over and machine set up.

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REJECTION:

Many printers are least bothered about the kind of wastage and rejections. Of course, not all pieces are perfect in any production process. Their bound to be rejections which have to be taken into account.

If customer sends job for printing and if they deduct any amount from your invoice due to rejection then you should inform your customer to send you extra pieces needed to cover up the tests, trials, wastage and rejections. You should inform them in advance that there would be certain amount of rejections in each lot and they should accept this fact and should not deduct any amount from your bill.

These days companies are spending millions in process standardisation and process control to minimise rejections. But many average screen printer do not even have weighing scale to weigh ink for repeat accuracy or any meter to make special colour match inks in-house etc. so they all go by an ‘approximate’ measurement done by naked eye and judgment. So, compelling screen printers to have a rejection percentage in ‘points’ in current situation is not practical.

According to the current circumstances & situation 15% to 20% rejection should be considered acceptable for an average screen printer who does have modern setup or right kind of skilled people with proper knowledge and process standardisation.

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INK WASTAGE:

If anyone claims that they do not incur any wastage of ink, it’s totally wrong. Whether you print 100 or 1000 pieces, there will be some amount of ink wastage, especially when printing with water based inks.

The wastage is higher in water based inks compare to PVC free – phthalate free plastisol inks. The advantage of PVC free – phthalate free plastisol inks is that after each job, you can recover every drop of ink back using sharp spatula (except some ink residues left on screens) and secondly the ink does not dry in the screens and there is no evaporation like water based inks.

So, if you are printing with water base inks 15% to 20% wastage of inks should be considered in your costing. This wastage includes the ink you leave on sides of screen and which gets thicker/harder after some time due to water evaporation. In some extreme conditions wastage cannot be reused.

The major factor of water based ink wastage is due to higher temperature in some countries and places plus mainly due to poor plant conditions.

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SQUEEGEE RUBBER & MAINTAINENCE:

The last priority item for every screen printer is ‘SQUEEGEE RUBBER’.

Printers never pay attention to squeegee which is the most crucial tool in the management of quality in printing.

Most screen printers may expect that the squeegee supplied with the machine, should last for years and years! Even the maintenance of the squeegees are so bad and they are never sharpened.

I have seen printing companies where they use squeegee for years unsharpened! Printers should understand that squeegee life is limited and its hardness starts diminishing from the original count (strength). At DMI we change squeegee after its hardness is diminished or if the length reduces more than 5 mm after frequent sharpening.

Even good quality sharpened squeegees can reduce your ink consumption by 5% to 10% in some extreme cases.

Please be aware that the squeegee has a limited life, and hence it should be replaced based on certain ‘weakening’ criteria. So, printers using automatic machines should consider the cost of squeegee while working on costing.

ELECTRICITY CHARGES / LABOUR CHARGES / OVERTIME CHARGES:

Many printers do consider electrical & labour cost but just for a rough estimate.

But the cost is not added on ‘per piece’ basis, because the electrical & labour charges will completely depend on the lot size. E.g. the cost of electricity & labour to print 100 or 10,000 piece will remain the same, but it will change drastically based on the lot size due to change over time, downtime, wastage of materials, and time wasted by labours during job change over. In this case the price cannot be the same per colour for 100, 300 and 1000 or more…

So, electricity, labour cost and overtime charges very much depends on the lot size, setup time and change over time.

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PLANT & MACHINERY / MAINTAINENCE CHARGES / SPARE PARTS:

Your plant and machinery requires regular maintenance. So if you cannot generate enough profit you will have to compromise on the maintenance of your plant and machinery which indirectly reduces the life of your machines and thus it will affect production and quality.

Better to deposit some amount every month in a separate account for safety and for maintenance of your plant and machinery like machines, generator, vehicles etc.

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ADMINISTRATION COST:

Your office administration cost in general should also be considered based on your monthly production.

E.g. If 10 people are working in your office for admin work with an average salary e.g. Rs. 15,000 per month, and let say your monthly production is around 100,000/per month and you have already added Rs. 1.50 in your costing. Now if your quantity shrinks down due to change over time or ink matching time or for any other reason, then it will directly affect your profit margin. But if you increase your production and productivity with same people, your profit will increase drastically.

FINALLY, FREE SAMPLING:

I know there is a trend all over to provide free samples to customers.

But I do not want to explain in details because by now you must have understood why one should not make free samples to customers. Because it cost you a lot of money for making screens, positives, setup time and other overheads.

While making samples for customer, you have to make special match colours. If the design works, you consume those inks; but if the design fails, your matched ink has to be used in other jobs or it remains in stock and has to thrown after some time.

That’s the reason why DMI has introduced a new system where in you only have to keep stocks of basic 14 Pantone colours, and all your designs will be printed using those limited colours. This will help you to minimise unwanted stock of inks and time to match special colour. Quite often, while matching special colours, there is possibility of wastage due to error in colour matching.

So, it’s not only the ink cost that you need to consider to add to your profit, but all the above factors should also be considered while working on your costing because today the major cost is labour, electricity, land, machinery and overheads.

Don’t struggle in production by using substandard, low quality inks, materials and consumables.

According to me don’t consider INK or EMULSION cost into your mind, if you increase your productivity, reduce machine setup time, reduce job change over time, minimise colour by doing proper separation of each designs believe me INK or EMULSION cost will be no where in account.

Most screen printers works so hard, spend so much time and energy to source cheaper substandard inks but fails to understand that the ink, emulsion cost even does not come into account if you increase productivity, reduce rejection & downtime, reduce setup & job changeover time. Don’t forget day by day overhead, labour cost land, electricity etc. will become very expensive compare to INKS & EMULSIONS.

Based on my experience and observation, I urge all the garment screen printers…

“Do not consider the costs that you feel to be considered and do consider the costs that you feel should not be considered”

So avoid further loss and start charging your customers for designing, screen making, positives, sampling and development charges on regular basis.

Because its better to maintain healthy competitions for long term business and don’t let your customers take the advantage of your ignorance & innocence.

To be more productive, reduce machine setup time, reduce job change over time, minimise colour & screens using high end colour separation software and to understand costing in details register to my workshop on advanced screen printing on textile.

For more information log on to: www.graficaindia.com

Be profitable and remain healthy in business.

Have a profitable week…

Bhargav Mistry

 

Register your seat/s in Technical Seminar at Screen Print India 2016 Expo

 

Dear Screen Printers,

I am glad to announce that during Screen Print India Expo between 6 to 8 May 2016 there are various seminars on interesting topics by renowned international experts.

 

Print Finishing with UV Special Effects Inks & Varnish

Vale Addition on Packaging & Offset Printing

PASJONATA – Innovative software for managing printing business and customers communication

By Jacek Stencel of Pasja, Poland

 

 

 

 

High-Performance / Industrial Electronic & Medical Applications

High-Tech Screen Printing 101 for senior & mid-management

Overview of Printed Circuit, Touchscreen and Conductive Prtg

By Mike Young of Imagetex Consulting International, USA

 

 

 

 

 

Simulated Process Dark Garments

Process Colour on Garment

By Charlie Taublieb, Taublieb Consulting, USA

 

 

 

 

 

 

To make your visit at the show productive the organisers of Screen Print India have specially called these experts from USA & Poland to conduct various seminars on interesting topics for screen printers who wants to grow in their business and wants to be productive.

So all who wants to improve their skills and wants to learn from these experts and see new samples and products then kindly register your seats for free.

Never stop learning new ideas & techniques if this does not cost you any money.

HURRY UP… LIMITED SEATS…

 

Download technical seminar brochure in PDF to know detailed topics with descriptions.

See you soon at Screen Print India 2016 expo from 6 to 8 May 2016 at Bombay Exhibition Centre, Goregaon, Mumbai.

Don’t forget to see our 3 new innovative products of this year during the show.

Also meet all our overseas distributors who are coming all the way from various countries to celebrate DMI’s 10th anniversary and get a chance to network with all our past DMI students and workshop participants.

Have a great weekend.

Bhargav Mistry

Multiple Invitations on 6th May 2016

My Dear Friends, Well Wishers, Grafica Customers & DMI Participants,

It’s my immense pleasure to invite you on 6th May 2016 to celebrate DMI (Dhirubhai Mistry Institute For Print Education, Research, Technology & Training) 10th Anniversary year.

 

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Along with this historical moments we are also launching 3 new products at the upcoming exhibition Screen Print India 2016 at Bombay Exhibition Centre, Goregaon, Mumbai

 

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So once again it’s my sincere request to all of you to please be present as I would like to meet you personally, especially I am eager to meet all my workshop participants and students who have been my inspiration.

You will also see many new ideas, concepts, automation and innovative products which will boost your productivity and profits.

SPECIAL ATTRACTION:
For the first time my close friend and one of the jury member of FESPA AWARDS, Jacek Stencel of PASJA is coming all the way from POLAND to conduct various seminars on special effects screen printing on value addition and packaging.

He will also be carrying many samples for display where you will get to learn many new innovative & creative ideas which will directly help you to implement in your jobs.

You will also get a chance to interact with him and learn everything about special effects inks and designing. His creative samples and knowledge will help you to uplift your creativity and imagination process.

He will also display new ideas and innovative products which will help you to enter into many new areas.

His seminar will have limited seats and entry is restricted unless proper registrations is done online.

I shall put the time table of all seminars shortly with topics and all details about various international speakers who shall be conducting these seminars.

See you soon at SPI 2016 and be in touch with us for more details.

Happy Screen Printing

Bhargav Mistry

DMI Workshop and Reopening Update

Dear Friends,

Before I update you about my last workshop and DMI inauguration ceremony. Please note the dates of my upcoming WORKSHOP at DMI which is scheduled in August 3-4-5, 2015 and the registration has already started filling up quickly. As we have limited seats so kindly REGISTER YOUR SEAT TODAY.

Ok so lets continue…

Today, I proudly announce that your favourite institute for screen printing, DMI – “Dhirubhai Mistry Institute For Print Education Research & Training” has started training programs in full swing. Recently, I had conducted my first workshop on 8-9-10 June 2015 with 38 participants who were really lucky to be a part of this historic moment.

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Click here to view 8-9-10 June 2015 workshop photo gallery.

After a long break, GRAFICA has built one of the world’s finest and most advanced institute – DMI, dedicated to screen printing technology.

The new institute is located on Mumbai-Ahmedabad National highway No. 8, around 45 kms from Mumbai Domestic and International Airports, towards the north of Mumbai.

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DMI is now fully air-conditioned with complete humidity controlled plant. This demonstrates how a printing company should build a world-class facility and maintain higher standards. At the same time it also showcases how to run a cost-effective production process.

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Before conducting my first workshop, we had organised an informal ceremony cum get together on 5th June 2015 to mark the inauguration of the DMI institute and as also our new factory. The event was graced by around 175 guests, including our valued customers, manufacturers, distributors, dealers, industry friends, well wishers, DMI’s sponsors, media persons, etc.

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In my informal speech I thanked all the guests for gracing the inauguration of DMI. I was touched by their presence because they had come all the way from various places across India and abroad.

As a manufacturing company, by conducting workshops and training programmes, my company, Grafica is giving back to the society. Initially we had the challenge of getting materials free of cost. So, the first company who came forward to support us by supplying inks and chemicals free of cost, was Fujifilm Sericol, I thank Mr. M.N. Subramanyam, CEO of Sericol and his team, viz, Mr. Ganesh Krishnan and Raghav Rao.

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We then started getting support from Skyscreen, Indian Dyes Sales Corporation (IDSC), Colors, Print Dynamic, and Technova Imaging Systems, Nikhil Ahuja of NBA Studio, Pune for his constant design and creative support to DMI. These companies are also part and parcel of DMI’s success.

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So, I take the opportunity of thanking and acknowledging DMI’s sponsors. These companies stood by us by supplying enormous quantity of materials and consumables free of cost, of course worth million of rupees every year for research, education and training purpose.

I feel without their generous support it would not have been possible for us to impart free training and achieve success in our endeavour to educate printers.

I presented a Certificate of Appreciation and a screen printed Wine Box, to all our sponsors who have been generous all past 9 years to support us for our noble work.

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As always, media has been supportive to DMI’s activities. I acknowledge and thank the presence of Devang Sheth, Publisher of Screen Print India; Ramu Ramanathan, Group Editor of PrintWeek India; Narendra Parmar, Managing Editor of Printing Samachar, and Jignesh Lapasia, Publisher of ScreenTex for their personal presence at the inaugural function and subsequent news coverage in their respective magazines.

Click here to view photo gallery of our new institute DMI inauguration ceremony.

This year DMI will complete 9 dedicated years, teaching high quality screen printing process and technology. So far more than 1500 print professionals and students and over 700 companies had registered and taken part in our extensive 3 days workshops and hands on training programs.

Today I am proud to say that DMI is the only Professional institute in the world of its kind which teaches very high end screen printing, screen making, print finishing, textile screen printing and colour management all under one roof.

With our intense research we have developed high quality screen printing process so simple that anyone can easily adopt it in their existing company without doing too many changes or investments.

Many companies use high quality products or let’s say expensive products like inks, emulsion, fabrics and even machines but do they have any right knowledge to produce quality output? Even many companies use very expensive imported machines but simply fail to deliver quality just because the method of screen making or printing is wrong.

Moreover, many imported and local machine manufacturers do not invest their profits in training and to provide right guidance to printers. Year after year printers spend their huge profits in consultation or sometimes they have to hire expensive labours who tend to show off themselves as knowledgeable, just based on the ‘reference’ of working in a good company.

We at Grafica are very focused to give correct guidance and provide right knowledge completely FREE through our institute DMI to all our customers and industry professionals who want to “Learn More and Earn More”.

For professionals, we hold 3 days workshop every month on various topics/subjects, and for graphic students we have short-term training course for 3 months to 1 year.

Our workshops are mainly divided into three categories.

  1. Graphics and Serigraphy
  2. Print Finishing
  3. Textile

The information of all our workshops is announced through our website – http://www.graficaindia.com, and magazine – Grafica News India. To register your seats log on to our website regularly.

It’s important for you to know that we have limited seats and we allot seats on first cum first basis.

Meanwhile, based on my perception and experience, I would like to correct two myths in screen printing:

  1. Make screens outside and print in-house – WRONG. In fact I would say, make screens, colour separation, positive output etc. in-house and get your jobs printed outside. Because screen is the heart of screen printing. “Good Screen = Good Prints”. If you wish to print in-house then it’s very important to make screens and do all separation also in-house to have full control on quality and output.
  2. Most screen printers especially in textile and garment printing believe that total quality is only achieved by using very expensive automatic imported machines. But as per my evaluation, to achieve 100% quality in screen printing, first you need to have proper knowledge and experience in the following areas to achieve high quality output and the ratio is:
    1. 40% in screen making
    2. 40% in pre-press like CMYK, Spot Process Separation, RIP and Graphics Software, Correct positive output, grey balance, dot gain compensation, linearisation process of the whole process, CMYK and Monitor colour profiling, etc.
    3. 10% on ink chemistry because if you buy inks and chemical from a reputed company most of the technology and chemistry taken care by the manufacturers itself.
    4. 10% knowledge of machine setting, squeegee, screen setting on press and environment control in the printing and screen making department.

In general, even any expensive imported automatic machine can only deliver 100% results if one has proper knowledge and experience in Pre-Press and Screen Making which is very important.

Otherwise don’t get fooled aways by paying double or triple the cost for any imported screen printing machine assuming everything is done by machine because you will only achieve 10% to 20% result if you do not have proper knowledge in Pre-Press and Screen Making.

At Grafica, we do not just sell our screen printing machines like others. We are more focused on education and to empower screen printers with right knowledge, especially in screen making and pre-press. To this effect, we are adopting new technologies and systems to improve quality and simplify printing. Ultimately, we are working hard to raise the level of Indian screen printing to international standards.

One of the major problems in process colour screen printing (halftone) is moire. As a result printers engaged in halftone printing are gradually moving away from screen printing. DMI is now focusing more on how to eliminate moiré problem in screen printing.

To know how join our next DMI workshop on 3-4-5 August 2015.

Come to Learn More and Earn More at DMI.

See you soon in one of my workshops and training programs.

Screen Printing Zindabad…

Bhargav Mistry

I have listed down few important topics and points which are covered in all my workshops. These topics are covered in detailed during my theory sessions and I also explain these points practically which is the main reason why people like DMI because showing it practically helps any ordinary printers to understand the process well.

Day 1:

  1. Colour management, ICC Profiles & Grey Balance
  2. How to make ICC Profiles of your own device, press and inks
  3. GCR, UCR, Ink Densities & Max Ink Coverage
  4. RGB to CMYK to SPOT Colour separations
  5. CMYK and Spot Colour Separation using various high-end graphics softwares
  6. RIP (Raster Imaging Processor) software for positive output directly on Inkjet Films and Thermal Image Setter
  7. How to keep trapping in CMYK to compensate registration in printing
  8. Halftone Dots and how to avoid moire using Moire Guard
  9. Types of halftone dots and shapes
  10. What is LPI, DPI and PPI
  11. Image size and resolution
  12. Calculate LPI vs Screen Mesh combination
  13. Calculations of minimum printable dot size and line thickness on a particular screen mesh
  14. Understanding about commonly used Digital Files like TIFF, JPEG, EPS, PSD
  15. How to increase low resolution image to high-resolution without much compromising quality and sharpness to certain extend (SHOWING FOR THE FIRST TIME IN DMI)
  16. New generation halftone screening techniques (SHOWING FOR THE FIRST TIME IN DMI) which completely avoids moire in screen printing and to achieve digital quality image on a traditional screen printing machine.
  17. Process Linearisation right from software to positives output using reflection densitometer
  18. Monitor, press, inkjet printer calibration
  19. Monitor, press, inkjet printer profiling
  20. Complete workflow of various software to positive output to match colour (WYSIWYG = What you see is what you get)

And much more…

Day 2:

  1. Screen Mesh Geometry
  2. Woven Mesh, Finished Mesh & Weaving Direction
  3. Types of fabric weaving
  4. Fabric composition and types of threads
  5. Advantages and usage of various type of screen mesh and its applications
  6. Mesh selection for a particular job
  7. Calculations of minimum dot and font size printable on a particular mesh
  8. Functions and types of screen frame profiles and selection
  9. Frame size to print area ratio and calculations to achieve close tolerance printing
  10. Understanding about off-contact distance, peel-off setting
  11. How to achieve minimum off-contact give minimum squeegee pressure and still achieve high quality prints
  12. Screen tension meter and how to achieve max screen tension
  13. Types of screen stretching devices and its advantages
  14. How to achieve proper registration between each colours
  15. Screen frame preparation and types of screen adhesives and application
  16. Cause of screen tension loss
  17. Mesh degreasing and chemicals to prepare screen mesh before emulsion coating
  18. Stencil selection based on various types of inks and applications
  19. Diazo Photopolymer vs SBQ Photopolymer emulsions
  20. Linearisation of exposing system to achieve optimum exposing time
  21. How to achieve good edge definition using various emulsion
  22. Various emulsion coating methods and techniques
  23. Emulsion coating variables
  24. Proper emulsion drying process
  25. Learn how to setup a proper screen making department
  26. Tools and instruments required to make good quality screens
  27. Complete stencil reclaiming techniques and various type of chemicals and solutions
  28. How to make and expose thick film for high density printing
  29. Chemicals to remove ghost image
  30. How to increase life of screen mesh and get optimum print runs

And much more..

Day 3:

  1. Print Finishing, learn various types of Solvent and UV special effect inks and varnish like Gloss, Matt, Reflective, Coral, Bubble, Wrinkle, Fragrance, Thermo-Chromatic, Temperature sensitive, Glow in dark, Metallics, pearl, thick ink printing for special effects and braille, crackle, florescent and much more…
  2. Special effects screen printing
  3. Process Colour Screen Printing
  4. Machine setting
  5. Setting optimum squeegee pressure and speed
  6. Off-contact and Peel-off setting
  7. Importance of squeegee sharpening
  8. Types of squeegee sharpener and grinding wheels
  9. How to avoid squeegee lines during printing
  10. How to maintain squeegees very sharp in long runs
  11. Selection of squeegee shore hardness for particular job and substrates
  12. Types of squeegee shore hardness meters
  13. Types of squeegee and importance of squeegee angles
  14. How to measure the life of squeegees
  15. Proper storage techniques of squeegees and flood bars
  16. Correct selection of flood bar and profiles
  17. Use of reflection densitometer in CMYK process colour screen printing
  18. Press linearisation techniques
  19. How to compensate dot gain/loss on press
  20. Proper use of UV and maintenance of UV Curing Lamps
  21. Setting optimum UV speed to achieve correct intensity using various UV Meters
  22. Various types of dryers and ink drying techniques
  23. How to achieve smooth halftones and gradients on press
  24. Proper registration techniques
  25. Learn how to change over quickly between each colours in less than 5/10 mins
  26. How to use guides and registrations system for all colour
  27. Learn various productive methods and techniques to minimise downtime
  28. Basic maintenance of various machines to get consistency in quality
  29. Proper storage techniques of positives
  30. Complete workflow right from setting the machine to final print

And much more…

Five Trends in Screen Printing Process

August 25, 2013 3 comments

Trend No. 1: Fast changing image of screen printing:

Image

The very mobile or high end smart phones or iPods, tablets that you are holding in your hands have the imprints of screen printing. The helmets you wear, the bike you ride have designer decals on both sides; the car you drive has the speedometers and dashboards – all screen printed. If you are a cricket fan, notice that almost every bat has multiple designer stickers screen printed, and t-shirts, helmets, PVC cheer sticks, balloons, or flags that the cricket fans are holding in the stadium – all screen printed. And do not forget, we are living in high technology electronic age. Every electronic product that you use has a PCB (printed circuit board) inside, screen printed of course.

A high level team of printing company engaged in automobile and aeronautic decals printing and high end graphics, walked into Grafica’s stall at Gulf Print & Pack’13 in Dubai. During the discussion, the gentlemen did not mind sharing with our team that they have as many as 30 semi – automatic and fully automatic screen printing machines! This is the quick glimpse of fast changing trend in screen printing.

So, screen printing is more than what people may tend to think about printing visiting cards, letterheads, invitation by using out dated and tedious method what we call “manual screen printing”. Screen printing is an artistic as well as technology oriented process. From its age-old method, ‘silk’ screen printing has transformed into an advanced technology.

Its distinct advantages: It has its own distinct advantages: versatility, suppleness, wide range of applications, brightness and solidity of colours of outdoor applications, possibilities of special effects in graphic and textile; and wide range of presses available for different applications – Multi – colours press very large size for graphic applications; Multi-colours rotary screens to print textile in roll; possibility of combination with other imaging or printing process (offset, digital, etc.).

The visual impact that screen printing process can create is simply incredible. The durability of the inks, the vibrancy of the colours, especially considering the harsh outdoor weather conditions for outdoor applications such as automobile decals, helmet stickers, indoor/outdoor advertising display boards, etc, (it withstands sunlight, rain, snow, wind, etc).

Applications, unbound: Screen printing has wider applications in commercial graphics (packaging included), industrial (almost every industrial segment needs the imprint of screen printing process), garment decoration and textile printing as summarised below. (It is virtually impossible to list out total number of applications of screen printing process).

Commercial Applications:
• Posters
• Billboards
• POP/POS
• Displays
• Stickers/Labels
• Signs
• Flags
• Packaging
• Value addition on offset printed commercial and packaging.

Daily necessaries:
• Toys
• Stationery
• Sports goods
• Art (Serigraphy)
• Cosmetic containers
• Toiletry containers
• Wooden products
• Glass & ceramics
• Plastic Cards, Credit Cards
• Foot wear

Textile:
• Sportswear
• T-shirts
• Ladies/Mens/Kids wear printing (full fabric printing)
• Textile printing
• Heat transfers/Tag-less labels
• Caps
• Jute bags
• Cloth bags
• Garment tags, stickers
• Packaging for Garments/Saree/clothing

Industrial applications:
• Automotive decals
• Automobile meters
• CDs
• Parts of electric appliances
• Membrane switches
• Liquid crystal display
• Automatic vendors
• Metal name plates
• Print Circuit Boards (PCBs)
• Hybrid Circuits
• Solar Cells
• Mobile keypads, iPod, iPads
• Medical patches and many more…

Trend No. 2. Advancement in screen printing technology comes of age:

Image

“Necessity is the mother of all invention.” And that applies to screen printing as well.

So, now there are:

1. Screen printing machine (semi-automatic or fully automatic – alas NOT MANUAL tables anymore!)

2. Screen making set up thatincludes: polyester yellow mesh or fabric (alas NOT nylon mesh anymore); fabric stretching unit with tension meter; aluminium frames (alas NOT WOODEN FRAME anymore), emulsion coating equipment; screen exposing machine; screen drying unit, and other accessories.

3. The screen that is the imagecarrier (considered the ‘heart of screen printing’)

4. Squeegee (the ‘heart of thescreen printing machine’) supported by a ink coater

5. The substrate on which youprint which depends on the job. (Screen printing process can be used to print on numerous paper and non- paper substrates – both semi- rigid and rigid – pvc, wood, glass, tile, ceramics, fabric, metal, etc).

6. UV Inks, varnishes, UVspecial effects (and emulsion and chemicals needed for screen making) (to be forbidden solvent ink wherever possible since it is hazardous)

7. Drying system to print,depending on the ink used (UV curing, IR/Jet Air/Wicket Dryers as against racking system which requires huge space.

8. QC tools (like tension meter, UV thickness meter, spectrometer, etc)

Trend No.3 : Emergence of Multi-process printing solution & fast spreading value addition concept:

ImageIt is believed that screen, offset and digital printing will co-exist for different types of jobs. These days, many offset printers are ‘falling in love’ with screen printing as witnessed by us during various printing exhibitions. In the last couple of years we received more visitors from offset, packaging and digital than screen printing.
Perspective

1. Digital-screen combination: This is yet another good sign. There are many digital printers who have also screen-printing units to meet the market demand for ‘total print solution’.
2. Offset-screen combination for VALUE ADDITION:
3. Digital, offset, screen combination.

There has been a growing trend of many offset printers and packaging printers embracing screen printing process for carrying out print finishing in house instead of depending on outsourcing.

Why value addition?
Sharjah based Silver Point Printing Press has recently bought one more Swing Cylinder Press with inline UV from Grafica to meet the non-stop and growing demand for value addition which is offered with the application of various decorative UV to give touch and feel effect over duly commercial and packaging jobs.

In today’s highly competitive business environment, print buyers are certainly looking for something different which really differentiates them from their rivals. Ultimately, the packaging in a shelf carries its look, its power of attraction for the consumers, and eventually the feeling of touch, or we can rightly say, today packaging is all about sensation – look, touch, feel, smell. Same principle applies to all commercial jobs other than packaging – value addition is a must.

The most promising is the use of a wide range of ‘special effects’ thanks to the think tanks in the screen printing industry driven by FESPA, an international association of various national printing associations including India.

UV Special effects currently used in the market are:
• Commonly used UV Matt and Gloss
• Pearl
• Metallics
• Fluorescent (glow in the dark)
• Scents / Rub and sniff
• Emboss
• Glitter (silver and gold)
• Sand
• Sensation
• Abrasive
• 3D reflective
• Crystal
• Rough finish
• many more…

Trend No. 4: Focus on Quality, productivity & Standardisation:

ImageToday, with automatic precision machines, it is possible to get a result that years ago would have been a pipe dream. For example, by manual screen printing reproducing photorealistic images on t-shirts was next to impossible, but now with automatic direct to garment textile screen printing machines, garment printers are able to print what the customers want with speed and accuracy.

In India, many of the large screen printing units are matching to international standards, and beyond, in a competitive marketplace because of use of high-level equipment and high – priced consumable supplies.

The industry (customers) allows minimum tolerances for the rejection besides mandating for Just in Time production and deliveries. Today, there exist different systems designed to help the screen printers to achieve better result. But it revolves around the simple concept or standardisation of the entire screen printing process.

Also, Screen printing industry is now waking up to the reality of UV-age. More and more screen printers are now adopting UV and dumping the foul smelling solvent which many feel a curse to the screen printing. Yes in some areas such as decals and industrial printing UV has not made successful inroads and still they have to use only solvent inks.

Shift from manual to automation: In the last decade, there has been steep increase in the number of screen printing machines and UV curing system (also screen making set up) sold in the last couple of years than it was five to ten years ago. There has been a big shift from manual to semi-automatic and now fully automatic system. More and more printers are now adopting automation and using quality raw materials, process standardisation, documentation of parameters for each job since in screen printing every job is a new job involving unique process parameters, use of materials (inks, chemicals, mesh, etc) with different specifications.

Over 50 companies engaged in garment manufacturing as well as garment printers (job workers), and also jute bag manufacturers, have installed our automatic direct to garment screen printing machine along with complete screen making system who had huge manual long tables.

Trend No.5: Growing urge for Education and training:

ImageScreen printing is now quicker, cheaper, produces better quality images and offers a number of special applications. Having advanced machines in place is not sufficient to run a profitable screen printing business. Being able to truly master printing high quality images, using the screen printing process, also takes much longer, because there are a number of variables involved.

Since we started workshops (always houseful with average 50 participants) in our DMI institute in 2006, till today over 2000 printing professionals (owners and staff) from India, USA, Europe, Middle East, Africa, Bangladesh, Sri Lanka, Nepal, etc, (screen, offset, packaging, flexo, textile printing segments) attended our 3-day workshops. They were of the opinion that without proper knowledge, screen printing technology cannot be used in a profitable manner.

Conclusion:
I would conclude by saying that while technology is the lock, education is the key to unlock the numerous opportunities in screen printing. I leave the screen printers to decide whether to take both (technology and education) or anyone! Those who grab both will stand winners in the market.

Key to success is technology adoption and knowledge up gradation!

Image“Two years ago, when I saw some wonderful creative samples at DMI institute, I realised the potential of screen printing process … I strongly believe, in screen printing every step is a ‘science’. So without learning this ‘science’ nothing can be printed qualitatively. By learning new techniques we can assimilate it in our daily practice. Mr. Narendra Paruchuri,
Managing Director, Pragati Press, Hyderabad

Image“You simply redefined the “Screen Printing Industry” of India to a different dimension. In the last six years your institution and activities have grown to multiple folds and you created significant mark in the chosen field. Nobody in India has approached screen printing so seriously and you created an international bench mark for the Indian screen printing industry..” Prof. Dr. Rajendrakumar Anayath, The Technological Institute of Textile & Sciences, Bhiwani, Haryana

Enjoy this cool Sunday…

Bhargav Mistry

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