I learnt an unusual idea from Bhargav to earn millions

I was thrilled to hear this comment from one of the participants during my recent workshop on 19 to 21 August 2010 at DMI (Click here to view the photo gallery).

Bhargav Mistry at the recent workshop at DMI

Bhargav Mistry at the recent workshop at DMI

Participants at DMI attentively listening to Bhargav's presentation

Participants at DMI attentively listening to Bhargav's presentation

This time in my workshop at DMI the subject was to integrate process color screen printing with value addition especially on PP flute board commonly known in India as Sunpack.

I see lots of school & college going boys and girls have one portfolio bag for keeping their drawing and project work. Even my daughter has two bags. But all her friends including my daughter has a standard black color bag.

The idea of making portfolio bag on Sunpack strike my mind once when I went to drop my daughter at her school I saw not only my daughter but almost all her friends had some fancy stickers or wordings or paintings done on the boring black color standard bag because currently there are no options for the colorful youth.

In that case I thought its a good idea for companies to market their products like jeans, t-sirts, cosmetics etc. targeting youth. This way they can market their products every efficiently because the youth have more impact of such creative ideas and concept.

Also till today many screen printers prints on Flute boards (SunPack) day and night for making danglers, POP with cutouts but till today no one has thought exploring various other unique possibilities on SunPack mostly in packaging to generate more revenues and stay ahead of competition.

So in the recent workshop at DMI I demonstrated how to produce such high value PP flute bags with special effects. The name of the job was “JUMPING JEANS”. When it comes to special effect many printers only think of commonly used Spot UV (Gloss, Matt) and other varnishes on offset printed jobs and wedding cards.

DMI's creative bag screen printed on Sunpack (PP)

DMI's creative bag screen printed on Sunpack (PP)

I had ordered this material duly CORONA treated from the manufacturer to print directly with UV Inks specially developed for PP substrate to give better adhesion. While screen printing with special UV Inks for PP, I experienced poor adhesion on the substrate. Later, I discovered the problem was due to old stock. This required re-treatment of CORONA but since I do not have the CORONA treatment facility at DMI, I screen printed a special transparent base coat to utilize the same stock.

Once you apply this base coat you can there after use any type of UV Inks or if you want to avoid the base coat in order to reduce one more printing operation then you may use a CORONA treatment machine to treat the material immediately before printing. This machine is a good investment for any printer who use UV Inks on plastics. Its also useful for offset printers too e.g. they can pass all their non-treated sheets and later stack on the offset press to print with UV inks for better adhesion.

Please note that even though you use CORONA treated substrates you need to use a specific UV Inks for that particular substrate. But there are special base coats for each substrate and once applied through roller coating or screen printing machine you can thereafter use any standard UV Inks.

I screen printed this transparent base specially developed for PP using a 120 mesh with a soft 65-90-65 shore hardness, triple durometer PU squeegee.

There after I screen printed complete image on 180 mesh count using 100 LPI fine dot screen because this bag will be viewed closely.

Once the screen printing was over, I printed abrasive varnish using 77 mesh count on a jeans texture to give the real feeling of the material.

DMI's creative bag screen printed on Sunpack (PP)

DMI's creative bag screen printed on Sunpack (PP)

The front image was over printed with gloss varnish to increase the aesthetics using 165 mesh count.

On front and back of the bag I printed a strip of golden glitter to give a sparking effect. The glitter varnish was printed on a 24 mesh count.

On the rear side “Jumping Jeans” title with a stylish font over the Jeans texture was screen printed using bubble varnish using 77 mesh count to give a bubbling effect.

On the top and bottom portion I printed with wrinkle varnish to give a nice leather kind effect using 77 mesh count. It’s important that if you want to get a wrinkle textures you need a special UV Lamp.

By the was at Grafica, we also supply wrinkle lamp system along with our UV dryers as an optional.

The Grafica & DMI logos were screen printed with special metallic orange ink using 120 mesh count.

DMI's creative bag screen printed on Sunpack (PP)

DMI's creative bag screen printed on Sunpack (PP)

On both the sides the enclosures were printed with golden pearl inks using 77 mesh. A UV matt varnish was overprinted on the golden pearl ink to give a water mark effect using 180 mesh.

The complete job was standardized using 65-90-65 shore hardness PU squeegee rubber because of the uneven surface of the flute.

VERY IMPORTANT: We pulled the squeegee parallel in the direction of the flutes because pulling across the flutes will dramatically increase the possibility of skin collapse between the flutes. This occurs because as the material is heated by the UV light it softens. If the squeegee is traveling with the flutes, it will be supported by all the flutes decreasing the likelihood of skin collapse. We also kept our squeegee pressure as low as possible to avoid crushing of the substrate.

There after we fabricated the bag to make the final product.

This job was screen printed live with various special effect during our recent workshop at DMI on 19 to 21 August 2010.

Since last two session M. P. Raghav Rao, GM, Technical & Manufacturing of FujiFilm Sericol India Pvt. Ltd. has already associated with me in my workshop to talk about last trends in Ink technology.

Raghav Rao with Bhargav Mistry

Raghav Rao with Bhargav Mistry

This time we had a special appearance from Adobe System India Private Limited, Akhil Kuruppan (Regional Sales Manager – West, Creative Business) & Rajesh Patil (Manager – Creative Solutions). Adobe already one of the sponsors of DMI’s educational activities for design software support. So in this workshop upon my request they both came to see what content I cover up in my workshop as far as Photoshop and Illustrator is concern. Rajesh Patil who is also one of the GIPT mumbai student with an experience over a decade in pre-press and design softwares will be joining me in some of my fourth coming workshops at DMI. He will mainly focus of Adobe Creative Suites and topics related to printing technology.

L to R: Bhargav Mistry, Akhil Kuruppan & Rajesh Patil

L to R: Bhargav Mistry, Akhil Kuruppan & Rajesh Patil

In our next job workshop you will be able to see more creative ideas on packaging with special effects. As the wedding season begins we are also creating a unique wedding box with cards inside never seen anywhere… because unusual screen printing happens only at DMI…

So to learn more and earn more register for my next workshop at DMI…

For registration log on to http://www.graficaindia.com

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  1. sukhjinder
    September 16, 2010 at 5:20 pm

    hello respected host

    i wanna know abt the concept of these thing, i allured so much,

    guide me

    Like

  2. September 17, 2010 at 7:53 pm

    I want to learn advance screen printing
    im graphic designer since 12 years and before 12 yeats im screen printing worker
    now i have my own business and i want to grow my business

    Like

  3. September 21, 2010 at 4:33 pm

    dear bhargavbhai,
    what an idea sirji!! converting the flute into a beautiful accessory for the college students. I am also happy to see the sponsors actively participating in the seminars.
    regards
    mustafa

    Like

  4. Deven Jasani
    September 29, 2010 at 2:04 pm

    Bhargavbhai

    Have atended the seminar of yours twice in Ahmedabad

    Would like to know about serigraphy which involves screen printing

    Like

    • September 29, 2010 at 3:54 pm

      You can buy a CD on serigraphy written by Michel Caza which carry tons of information not only about serigraphy but also about UV Inks, Screen Printing and Making etc. For the cost you may kindly email marketing@graficaindia.com and mention about the CD of Michel Caza and they shall let you know the same.

      Like

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