Along with the many details for processing an order, there are a number of steps that happen between print request and the packing of the finished screen printed product.
REVIEW ART SUBMISSION
If artwork is customer supplied, we must determine if it will print well. We review each piece art and offer suggestions and recommendations for better printing if necessary. To help, we’ve developed an artwork requirements guideline based on our experience over the years.
Once the artwork is determined good for printing, we’ll email you a digital art proof showing a mock up of the design on the garment style and color(s). On this proof, we’ll list out the exact imprint sizes and list the pantone colors we intend to use. The mock-up is an estimate for sizing and location. It’s at this stage we request your artwork approval so that we may proceed with your order, so if you have any questions or concerns, please let us know!
COLOR SEPARATION AND FILM OUTPUT
For each color in a design, we produce a piece of film that will become an individual screen. Each separate screen is put on press and loaded with a specific color to be printed. The process for deconstructing the art into it’s single color components is called color separation. Once the art is separated, we output a film positive for each color.
Screen exposure or “burning screens” is the process of creating a screen stencil from the image on the film. A pre-stretched screen is coated with a photo-reactive emulsion and dried. The film is then adhered to the coated screen and exposed to high intensity light for a defined period of time. After exposure, the screen is sprayed with water to remove the emulsion from the image area.
SCREEN PREP FOR PRODUCTION
Once the screen has dried from the wash out, we prep it for the production run. We apply block-out to the emulsion areas outside of the design. This prevents the occurrence of pin-holes (tiny holes in the stencil that allow unwanted dots on a shirt) and helps stabilize the stencil for the entire production run. The edges of the screen are taped off to prevent other ink leakage and allow easier clean-up.
While the film is being printed and the screens are being made, the ink department is pulling the ink and stationing it in a holding area for the press operators. Based on your order, we either use our stock inks or custom mix requested pms inks with our pantone color matching system.
There’s actually quite a lot of variables that are addressed each time a screen print design is set up on press. Depending on the design and desired outcome, press operators consider the amount of off-contact, squeegee speed, squeegee angle, durometer and other technical aspects of screen print. After the initial set up, these settings are recorded so the set up takes a fraction of the time for a re-order.