Fit a Need to a Product

In a previous article titled “Matching Screen Frames to the Need” (Printwear, March 2007), I highlighted frame types. Again, I would point out that the most logical method of choice is to evaluate the needs of the print project and focus on the frame product’s features. Certain specialty inks require very high and consistent tension best achieved with retensionable frames; other situations may find that the least expensive and disposable wood frames will serve in the most economical way.

The most common problem is that often the initial price of the frame is given far too much attention, considering that the final and least-expensive option may in fact be the highest-performance retensionable frame.

Take time to do the research needed and continually evaluate your shop needs to make sure you are not missing the real economical choice for your particular use of frames.

Frame and Print Size

Often, start-up shops fill their initial frame needs with smaller “manual sized” frames, then quickly outgrow the frames when they start finding orders where larger printed art areas are required, or they find the volume demands of the shop require an automatic press. Costly and frustrating, replacing or adding a full compliment of larger screens to the working collection can be an unexpected financial burden. Consider starting out with the frames you’ll likely be using a year from now.

Cycle Optimization

Every shop requires enough screens to complete a daily cycle of production with additional screens to handle a set number of future jobs, along with covering the lag time for reclaiming and cleaning. Recently I helped develop procedures in students’ shops that combine quick processing, step-eliminating film applications, and quick drying so as to lower the needs for large numbers of screens. The goal is replacing or complementing large collections with effective methods and techniques to maximize the efficiency in the screen cycle.

A quick look at an optimized processing cycle based on retensionable frames is in order:

• When our theoretical job is finished, the inks are removed and an “on-press wash” is used to remove all but a residue from the screens; block-out tape is removed, and the screens are finally removed from the press.

• Screens are taken to the reclaiming washout booth and submerged into a tank containing an ink degrader and stencil remover combination. Once so treated, the ink residue is lightly scrubbed, then rinsed from the screen, first with low-pressure, then with a high-pressure washer. If an ink-stain remover is required, the mesh is so treated at this time. The screens are then set aside to dry.

• Once a new print job’s positives are available, the required screen meshes are pulled from the screens and set aside. If a new mesh type/count is needed, a suitable retensionable frame has its current mesh replaced with the new mesh. Once prepared, the screens are washed with a combination degreaser and capillary film chemical and, while wet, the required capillary film type and thickness is applied with a roller, directly onto the wet screen, eliminating a drying step and preventing contamination.

• The addition of an effective drying cabinet lower drying times to less than 20 minutes. When dry, the screens are exposed, developed, and dried for the final time, making them ready to prep for the next printing job.

Of course, this example may not be the most effective for your shop’s requirements, but it illustrates how careful, creative, and targeted planning can lead to excellent profit-producing results.