16 Steps to get the print job done!
One of the biggest and most often asked questions we get in the screen printing industry is why does it cost so much for one shirt, or two shirts or even 10 shirts. Typically the ones we get this question from are those that want to get a handful of shirts for fun or for a small startup business and they aren’t wanting to spend the money it takes to get their custom screen printed apparel. Also they want a very elaborate design with tons of colors. Below is a chart that shows each stage that goes into the screen print job that every client’s job flows through from start to finish.
Step 1
Client comes in or calls and we have to consult with them to find out ALL the info for the job they are wanting to see come to fruition.
Step 2
Next we have to place the order for materials that will be used for the client’s order.
Step 3
Then we have to send the job info to the art department so they can work their magic. It requires their total magic if they have to create the art/custom design. If the client has the art and it is 100% ready then this makes the task easier and faster for the artist.
Step 4
Depending on step 3 we then need to get the approval of the artwork.
This depends on if the client supplied the art or not in step 3
Step 5
Then the artwork has to be printed onto a film material so the image can be used in step 8.
Step 6
Each screen that will be used (depending on how many colors) has to be clean and free of greasy residues, old ink, old emulsions and so on and then dried to start the next step.
Step 7
Once the screen(s) are dry from the previous step the screen(s) have to be coated with a photo emulsion and set to dry a second time so the positives made in step 5 can be used in the next step.
Step 8
Now we have to marry up the positives to your job made in step 5 with the screens made in the previous step and expose the emulsified screens under a UV light for a specific amount of time to “burn” the image into each screen needed for the job you need produced.
Step 9
Then we have to wash out each screen to wash out all the emulsion that didn’t burn under the UV light to open up the screen where the image will be on the screen and then dried a third time so the ink will have an opening to be pushed through during the printing process in step 12.
Step 10
Once each screen is dry we then need to tape up the edges of each screen so ink will not get in between the screen and frame edge, or make ink transfer on parts of the customer’s product where ink isn’t supposed to be transferred to and then send the screens to the press.
Step 11
Each color used in a design has to be aligned to each consecutive color so you get a great looking end result for what you paid for. This can be a tedious process and unless the job is only one color it can take a good 20 minutes or more to get them aligned properly and test printed and inspected to start the production run.
Step 12
Here is where the production starts to gain speed. Once the previous step has been accomplished each piece is put onto a platen, the screen lowered and the ink squeegeed onto each individual piece. Then the piece is removed and depending on what type of ink and substrate being printed either has to run through a curing oven or allowed to air dry so the printed image will be as durable as it needs to be.
Step 13
After the last piece is printed and cured they need to be inspected to make sure they are correct, counted and boxed to pass on to the customer.
Step 14
After the last piece is printed and boxed the job needs to be broken down and taken off the press so the next job can be aligned and printed for the next client in line. This requires each screen to be cleaned of all ink, tape, each squeegee to be cleaned of ink and each screen taken off the press.
Step 15
Each screen now needs to either go to be reclaimed or catalogued to be used at a later date and new order.
Step 16
Customer is then called and invoiced to set up pickup or delivery and payment of product.
As you can see from the steps above, each custom screen print job is a very in-depth process and that equates to time and resources that all have to be accounted for; which all contribute to the overhead of the business. You add more colors then that takes more time during steps 5 thru 12 and steps 14 and 15. When you are ready to place your next order, contact us so we can get started on your next awesome design!
Wow this actually explains things well. I have always thought screen printing was something simple and always questioned every company’s prices, but now I realize it isn’t so simple and will actually have a higher respect for screen printing companies pricing from here on out. Also I would like to thank you for the beautiful shirts you printed for us last time.