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| January 2006 issue of PRINTWEAR |
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Athletic-Number
Printing
There’s gold in them-thar numbers
by Douglas Grigar, Master
Screen Printer
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(A version of this article originally appeared
in the Jan 2006 issue of PRINTWEAR.)
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I’m here to tell you
that athletic printing just doesn’t get the respect it deserves!
Direct screen printing of athletic numbers is a growing business with
no signs of diminishing. One of the most irritating statements I hear
in the screen printing industry is some form of, “It’s just
athletic printing,” as if it were not a challenge, as if the proper
selection and use of emulsion, equipment, and screens makes little or
no difference in the chance of success.
A dangerous miscalculation is to assume that there is little or no challenge
to athletic screen printing. Making choices based on “How hard can
it be?” is thinking that will quickly return to haunt the uninitiated.
While there are many tips and tricks applicable to athletic and number
printing, this article will review some of the larger, seemingly hidden
and often overlooked issues that newcomers to athletic numbering have
to tackle (see Figure 1).
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[Figure 1: Athletic screen printing
is a large demand area of screen printing, but there are challenges
to what is often perceived as one of the “red-headed step-children”
of our industry.]
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Time and Production Factors
Individual numbers printed on to any garment will take drastically longer
to print than standard, multi-color print orders. Every printer new to numbering
should expect that production time can be two to five times as long as standard
printing. While printing efficiency will improve, numbering can never approach
the higher speeds of standards screen printing. The basic factors inherent
to athletic printing, particularly player numbers, extend the needed production
time. Specifically, thicker inks, time to load special garments, overcoming
issues with special fabrics (such as micro- and porthole-mesh garment fabrics),
and the general organization of the correct print for each garment contribute
to this extended production time.
One point often overlooked is the time required to clean screens from one
color to the next. High-speed numbering systems, while clearly the fastest
in actual print speed, take considerable time to clean completely, and are
particularly difficult and time-consuming to clean when switching from dark-
to light-color inks. The time required to clean large specialty screens
can often overtake the time needed to produce printed numbers using simple
die-cut stencils, or the additional costs of multiple sets of duplicate
screens for light and dark colors. The romance of high-speed numbering systems
(or even the slower “drop-in/key frame” number screens) is dulled
by the reality of difficult, time-consuming, house-keeping chores. Smaller
print runs and background chores can dictate your choice of printing method.
Organization
Nothing spoils a numbering order more than little Johnny’s parents
returning garments because the name, size, or number are incorrect. The
only way to prevent mistakes is thorough preparation and organization.
There is no such thing as “time wasted” organizing an athletic
order, because there is never an excuse for little Johnny’s expensive
sports jersey having the wrong number printed under a misspelled name.
Nothing can distract a printer more than a list of names, numbers, and
sizes in one hand, and a squeegee in the other. Accordingly, remove unnecessary
distraction by sorting the order before it gets to the loading table.
Safety pin pre-printed tags with all the needed information to a sleeve,
manufacturer tag, or collar of each garment (see Figure 2). Each garment
having such a mini-order form attached allows the printer to concentrate
on the complexities of the print, machine, ink, and dryer…and not
on coordinating a long list of particulars with a stack of garments.
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[Figure 2: Attaching a “mini-order”
to each garment with the particulars about the printing (e.g., names,
numbers, and sizes) takes pressure off the printer to sort and print
at the same time.]
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Space Requirements
Athletic screen printing, with its specialized equipment, will need additional
space for the press, special screens, and ancillary equipment. In particular,
the larger frame (and attachments) used in the linear numbering systems
are quite large. Storage of such screens is best in protected vertical cabinets,
rather than just leaned against a wall waiting for a sharp corner to damage
the mesh. Don’t forget the need for large table space for sorting
orders and the possible need for a heat press or two for applying transfers.
Heat-transfer presses are often needed to embellish areas that cannot be
reasonably printed on certain types of garments.
Chemical Compatibility
One issue revolving around screens with permanent stencils is the use
of cleaning chemicals (see Figure 3). The use of slow-evaporative cleaning
chemicals, traditionally referred to as an “ink degrader,”
an “on-press wash,” or a “screen opener,” is gaining
more ground as the industry searches for ways to prevent mesh staining,
and the desire to have safer and more “green” work conditions.
The use of soy, citrus, and slow-evaporative synthetic solvents in long-term
use, however, can soften photo-emulsion stencils.
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[Figure 3: Cleaning screens for color
changes or after using ink additives can often dictate the choice of
equipment because of the extended cleaning time required.]
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With stencils that play a part
in a continuous reclaiming cycle, slight stencil softening is of little
or no concern. But allowing stencils to lose harness when they are designed
to be used continuously, without reclaiming, can lead to loss of edge
definition and stencil delamination. Manual cleaning and abrading with
even soft rags only contributes to the problem (see Figure 4).
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[Figure 4: A) Delamination occurs as
the emulsion separates from the mesh along the edges of the stencil;
B) Softened emulsion damaged by aggressive cleaning with rags. (graphics
by Douglas Grigar)]
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4-A |
4-B |
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trying to prevent stencil “lock-in” and ink stains, that, when
presented with special cases such as long-term stencils, our standard procedures
could prove detrimental. I advise checking with your screen manufacturer
for potential solutions.
Garment Issues
Printers should be particularly vigilant in checking fabric content before
printing. Nylon and polyester obviously take individual, and considerably
different, plastisol ink mixtures to print successfully. There are particular
products and chemicals that will aid in your athletic printing needs;
be sure to contact your ink manufacturer (or search their web-based resources)
for complete details and recommendations on the use of their products.
Newer and exotic synthetic garment fabrics are often untested for printing
and there may not be a suitable ink available that would adhere to the
garment and/or not weaken or damage the fabric in the process. Every printer
should be aware that from time to time there will be garments that just
can not be printed without color changes in the ink or without washability
issues. One particular and problematic example is fabric that is coated
or treated with stain- and/or soil-resistant chemicals. The unfortunate
side effect of stain-resistant fabrics is that the treatments often work
so well that inks will not adhere to the fabric.
There is also a disturbing issue with athletic garments in which content
information is mistakenly mislabeled on manufacturer tags. Problems associated
with higher than noted polyester content are dye migration, sublimation,
bleeding, and adhesion.
Thicker = Hotter, Longer
Athletic printing is known for its thicker ink layers, both for abrasion
resistance and opacity. Printing athletic garments often dictates very
low mesh counts, where 60- to 80-tpi are common. Thick ink layers demands
higher temperatures and/or longer, slower trips through the dryer to properly
cure. It is not uncommon to be forced to send the garment through the
dryer multiple times and even turn it inside-out in order to apply heat
for a full cure on the bottom ink layer. (Porthole- and micro-mesh fabrics
often demand extra steps and time.) Every printer should be aware that
the heat and time needed for a total ink-layer cure is a balancing act.
Conditions must be correct for a complete cure without overheating the
garment, causing damage or (in the case of polyester fabric) dye migration,
bleeding, or sublimation (three distinct problems that look basically
the same, but are in fact results of differing processes relating to chemical
reactions and heat).
Don’t Trust the Pearl in the
Oyster
No manufacturer of equipment or supplies can stress enough the need to
practice and become familiar with the use of their products before you
start production of number garments. Most often, the word “new”
in a print shop should be translated as “warning.” Sufficient
time must be inserted into your production schedule, as customers typically
don’t want to pay for a “good try,” or for your “on-the-job
training.”
Often, print shops will take large orders or contracts for athletic screen
printing before they even order supplies and equipment. They too often
hope that all will be “easy enough,” then get themselves in
trouble when problems arise and production is held up. Shop owners often
expect workers, supplies, and equipment to instantly be able to meet pre-planned
(and often unrealistic) expectations. If not, they worry that production
is loosing money. To my way of thinking, this makes no more sense than
the old adage about the optimistic youth intending to pay for his meal
with the pearl he expects to find in the plate of oysters he orders for
dinner.
Athletic-Number screen printing is not all “doom and gloom,”
though. In fact, it can be quite profitable. But every shop must plan
for the extensive research, practice, and increased demand that is a part
of the challenge of number printing. Athletic-Number screen printing,
while challenging, could place your shop into the small minority of printers
enjoying the workflow and profit associated with this section of the industry.
Business strives for profit, but profit is the result of efforts, dedication,
and struggles with printing challenges. Customers are willing to pay handsomely
for your efforts. Logical planning can take advantage of a customer’s
willingness to pay for difficult problems. (graphics by Douglas Grigar)
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