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DMI is truly an International Screen Printing Institute!

July 23, 2017 2 comments

Hi Friends,

My recent houseful workshop had 19 overseas participants (South Africa – 10, Egypt – 5, Japan – 1, Nepal – 2 and Sri Lanka – 1). In all there were 59 participants.

DMI is now truly an international screen printing institute!

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There is a saying that sometimes photo speaks more than words. So let me share with you photos of my recent textile workshop.

CLICK HERE AND ENJOY THE PHOTO GALLERY

Have a nice & lazy Sunday…

Bhargav Mistry

Technical Tips by Bhargav Mistry, DMI – #3

In my previous blog post I had mentioned about Humidity control and I would like to further elaborate on this subject.

Controlling Humidity is very important and essential in screen making department. Few companies do have Air-Conditioned in their screen making department but that only will not help. Split/ceiling mount or wall mount units are all comfort AC’s and do not have humidity control system.

If you want to achieve high quality screens and repetition accuracy then controlling Temperature and Humidity becomes very crucial.

In DMI many times we keep screens till max. 15/20 day unexposed. Obviously under control environment and in total dark condition to prevent from light and to avoid hardening of screens.

To achieve longer shelf life from pre-coated screens do not allow screens to get expose to any kind of light including yellow light of your screen making room.

Once the coating is over and the screen is removed from the screen dryer. Keep those screens inside cupboards to avoid lights.

The main reason we could keep our pre-coated screens in perfect condition till 15/20 days is due to controlled temperature and humidity.

Alway try to keep humidity as low as possible at DMI we maintain between 50% to 55% RH and temperature 23℃ to 24℃
Humidifier_WhiteWestingHouseIf you are thinking about investment and running cost. Believe me its negligible compare to quality.

Currently in DMI we use centralised air-condition plant with inbuilt humidity control system.

But previously in DMI we were using White-Westinghouse Model WDE550. This machine consumes approx. 20 units in 24 hours which costs us max. ₹140/- per day which is very negligible.

It’s worth spending because the quality of screen will improves drastically. Plus you will always get repetition accuracy.

Especially when you use Inkjet films it will help a lot because I have observed people complaining of ink transferring on emulsion after exposing and there after the films can no longer be used.

The main reason for this is humidity or improper time given for emulsion to dry. The use of Screen Dryer is very much essential to achieve proper drying of liquid emulsions.

Investing on a humidity control system is very much essential in screen making department.

These kind of humidifier are available online on Amazon and Flipkart. The one which we use WDE550 cover approx. 550 sq. ft. easily (5500 Cubic Ft.).

“It’s vital that the amount of remaining moisture in the emulsion coat in the screen – when totally dry after coating (before exposing ), and also when dry after development (before printing) – remains under 4%. If it must resist to printing, especially in the part of India and Asia or in any other country when the humidity of external or internal air is above 70%. There are tools available in market which can measure internal emulsion humidity.” Says Michel Caza.

Below I have mentioned few important points if your screen making department has proper yellow lights, no windows to prevent outside lights, plus controlled temperature and humidity.

  1. Repetition accuracy
  2. Image Sharpness
  3. Reduce stencil breakdown during printing
  4. Increases quantity of prints
  5. Avoid inkjet films black ink transfer on emulsion after exposing
  6. Reuse inkjet films
  7. Reduces tackiness
  8. Increases pre-coated screens storage life
  9. Avoid pinhole problems
  10. Reuse screens after short print runs

So if you want to improve your screens, improve your screen making department first.

In my next post I shall highlight the importance each department and process.

Till then good bye.

Bhargav Mistry

Technical Tips on Screen Printing by Michel Caza – #1

March 8, 2017 4 comments

Bhargav-MichelCazaToday I will be posting my first Technical Tips. As my I have written dozens of technical articles on my blog but this new concept is designed to provide short and quick technical informations on screen printing technology.

Since it’s my first post, so I requested my GURU Michel Caza to kick start by posting one short technical tips.

Yesterday evening I requested him to send me few technical articles & tips so that I shall keep you posting one by one.

He was quite helpful to send me one quick article on Screen Making but there are many more to come from us and also from many other technocrats of this industry.

This is just a beginning, you will see many in-depth articles, tips, videos, visual to learn every day with many new innovative ideas.


Q – The small dots and fine lines printed disappear on the screen after stencilling?

Dots and lines too fine on the film
Respect the indications about the maximum possible fineness to reproduce

Dots and lines not black enough on the film
This can happen with films made by inkjet, not dark enough.
The sharpness, resolution, edge definition of the film must be perfect.

Colour of the screen mesh
Always use yellow mesh, avoid white mesh, to prevent light dispersion in the thread

Too coarse fabric or/and too large thread diameter
This prevent to print fine lines or dot : use S or T, thread diameter of 27 to 31 microns
in 120 to 165 thread/cm, plain wave (PW) if possible

Improper emulsion sensibility for fine lines definition and resolution
Choose a good emulsion, diazo (SBQ) or better, diazo polymer (wide latitude when exposing) with high amount of solid content.

Too many emulsion coats
As it must be exposed more, this causes the closing of the fines lines and dots.

Over exposure of the screen
Even with a correct coating of emulsion (1 coat, 1 + 1, or 2 + 1 maximum), respect the indication given by the Exposure Calculator.

Handling of screen under Improper light.
When the emulsion is dry, before and after exposure and beginning of developing with water, it is sensible to the light and can then be hardened, partially or totally. Then use yellow light in stencil room. When wetted on both sides of the screen , the white light can be used.

Poor contact in the exposing unit
To prevent any dispersion of the UV light during the exposure the contact between film and screen must be perfect. Check your vacuum pump or the rubber carpet quality which must be clean and without holes. Use a thread to the screen frame to permit a better drainage of the air.

Use of “UV tubes” light
I do not advise this because the UV light is not punctual enough and the dispersed light is not able to stencil properly line and dots under 100 microns. For fine lines, use a metal halide lamp.

No “light integrator”
Take care of exposure “time” which can drastically change during the day with the variations of supplied electricity. Use a light integrator which automatically measure and supplies the exact “amount of light” needed

Poor development of the screen.
If some emulsion remains in the finest lines or dot that should be totally open, those will be closed and of course impossible to print.

All the best from;

Michel Caza

NOTE: Kindly rate each post and also send your comments to help us improve on contents and topics.

DMI Introduces New Courses on Art & Serigraphy Screen Printing the CAZAWAY

September 12, 2015 Leave a comment

Before I continue writing about my last workshop update on textile (t-shirt/garment) screen printing I would like you to note my next workshop dates at DMI.

29 – 30 Sept, 1 Oct 2015
Workshop on Advance Screen Printing Process on Graphics, UV Print Finishing, UV Special Effects & Packaging

27-28-29 Oct 2015
Workshop on Advance Textile Screen Printing Process, Special Effects on Garments & Heat Transfers

If you wish to participate register online soon as seats are filling up quickly…

My 1st Workshop is on graphics, commercial and value addition on packaging wherein I shall mainly focus on two aspect of screen printing. On graphics side I shall demonstrate how to print moiré free, digital like quality graphics using traditional screen printing process with various UV special effects inks and varnishes.

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And on packaging side I shall demonstrate some innovative ideas to add value into your packaging products through screen printing process.

Here’s a video presentation of some of DMI’s finest special effects screen printed in my various Workshops & Training programs.


And on last day I shall just show some highlights about serigraphy (art screen printing) which is now gaining popularity in India. Since we have just started working on this new technique in DMI hence it will take few months to master on this subject and bring it into my workshops as a regular subject on this topic.

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In serigraphy screen printing many printers ask me why cannot we print serigraphy using high quality digital printing machine ?
The first reason is that if it is digital, it’s not “serigraphy” which is the latin name of screen printing ! This technic exists and the name of those prints is “giclée” or “digigraphy”.

There are many other reasons why we cannot but I shall highlight those points in my workshop but maybe the main reason is how can we add value addition and UV special effects in serigraphy after we print digitally. I mean unless it’s a flat bed digital machine we get a chance to register the job like traditional three guides system as we use in screen printing but how will you register the job on screen printing machine to add UV special effects etc. if it’s printed on a digital machines. Many experts have also informed me that even to register jobs printed on flat bed digital machines are also difficult to match because they are also not that perfect and dimensionally stable piece to piece.

So after a long break we shall once again demonstrate how you can earn through serigraphy screen printing using various UV special effects screen printing to add value in your arts and graphics.

I have observed than in India there are few serigraphy screen printers and most of them print cut colours (solid flat colours) without halftones so most of their arts do not have gradation and halftones and that’s the reason they end up printing 12-14-16 or some times even more colours but they can never achieve gradations in their prints and arts are all made of brush strokes and strokes are mainly never flat tints unless painted specifically with flat colours.

CAZA-3

So without gradations and vignettes one cannot product exact reproduction of the original art no matter how many colour are printed. Even the separation will take hours to divide image into special colours. As matter of fact, some American screen printers made and often still make serigraphy with 50 printed colours and sometimes more. In the past, Michel Caza printed one time in the seventies 100 colours just as a “challenge” ! But to avoid this, he invented in the sixties the “halftones without dots” that allows to print full colour jobs with between 9 and 14 colours. Then, and still now, he put this technique to 7 printed colours.

FROMME-DOUGLAS-PETER--1989-74X90cm- VERDIER-FABIENNE--2005-56X76cm-

There are many companies who print serigraphy on offset machine but those prints look very much flat when compared to screen printed serigraphy and that’s because of the ink thickness achieved through screen printing. But to print special effects one has to anyway depend on screen printing. Here again, same as above, if it is “offset”, it cannot be “serigraphy”. Fine art prints are then made in what is named “photolithography” a name coming from the old technique from which offset was invented name “stone-lithography”.

My guru Michel Caza in Paris, France is one of the finest serigraphy screen printers and in his company “Graficaza” he had one division mainly focused and specialised on serigraphy (art screen printing). This company succeeded 1984 to “Atelier d’Art Michel Caza” existing since 1964. Graficaza was sold 2004, but they stop to screen print Fine art and luxury POP and disappeared 2005! Even till today he still enjoys printing fine art and serigraphy near Paris, in the screen printing workshop of his friend, the now famous artist Fabienne Verdier. In addition to several serigraphies printed for and with Fabienne, he printed this year two serigraphies of his wife Therese, painter but also Yoga and Ayurveda teacher. Some of those serigraphies were given to the winners of Gold Awards in the FESPA competition.


I was one of his lucky pupil who got my training from him in 2003 when I visited Graficaza in Paris, France to learn from the master of screen printing.

Bhargav_At_Graficaza_France_13
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In fact here I would like to inform you that on December 2006, DMI was inaugurated by my guru Michel Caza and he conducted two workshops one after another and his second workshop was on serigraphy screen printing.

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So with all his blessings and knowledge today after 9 years I am proud to announce regular workshop on arts and serigraphy screen printing soon at DMI…

After he conducted his first serigraphy workshop in DMI, we continued to demonstrate serigraphy screen printing but very few screen printers had shown serious interest on this process because they had to invest on machine and good screen making system which was expensive those days and without proper equipment one cannot print high quality serigraphy.

But today I don’t see that as an issue because Grafica now has more than thousand’s of screen printers using our Nano range of products and out of those many have invested in NPL which includes of UV curing machine and 5-In-1 screen making system. Those printers who have screen printing machine, proper screen making system and UV Curing Machine can very well high quality print serigraphy.

So if you have already automated your shop floor and are seeking for some diversification in business or want to learn something new than this is the right time to invest your time and energy to learn serigraphy at DMI and learn how to reproduce arts and paintings using traditional screen printing process. So with the knowledge and technique given to me by my Guru Michel Caza lets all learn serigraphy screen printing the Cazaway process at DMI…

Screen Shot 2015-09-12 at 6.17.53 pmScreen Shot 2015-09-12 at 6.17.23 pm Screen Shot 2015-09-12 at 6.17.41 pm Screen Shot 2015-09-12 at 6.18.23 pm

Because at DMI you get to Learn More | Earn More.

Now report about my last textile workshop:

DMI_Workshop_20150825-232

In this workshop for the first time and now forever we will only demonstrate how to print digital like quality through traditional screen printing process on t-shirts and garments.

CLICK HERE TO VIEW COMPLETE PHOTO GALLERY OF OUR LAST TEXTILE WORKSHOP

Now at DMI I will only teach all garment screen printers how to achieve continuous tone printing through traditional screen printing process.

DMI_Workshop_20150825-329 IMG_2909.JPG IMG_2910.JPG IMG_2913.JPG

I am sorry if you want to still learn the traditional, outdated, dirty and ugly looking halftone dots (45, 55, 65 LPI etc.) and also want to understand how to avoid moire in screen printing than you will have to look for an outdated screen printing institute because at DMI the kind of process I teach there is no moire issue now anymore and in textile screen printing we never print rational halftone dots anymore. Hence in all my future workshop the topic “how to avoid moire in screen printing” has been removed forever because, I simply don’t need it…

In my three day workshop I demonstrated five variations and all with only Water Based Ink technology:

1. CMYK on white and light garments
2. Discharge & CMYK on dark garments
3. Under Base White (Khadi) & CMYK on dark garments
4. Discharge & Spot Colour Process
5. Spot colour process on under base white (Khadi)

And on the last day we also demonstrated heat transfers.

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All the above mentioned jobs were demonstrated using my separation technique and how one can print continuous tone printing and achieve digital like quality using traditional screen printing method.

Apart from this I also demonstrated many new techniques:


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How to mask complicated photos in less than one minute which was highly appreciated by many participant because some said to me that they sometimes spend hours to mask just one image and even then it’s not perfectly masked.

Lion_Black Lion_White

Complete workflow, file handling, PDF files, image correction and evaluation.

Color management and all about ICC profiles.

How to output correct linearised positives on image setter, inkjet printers and now for the first time we shall also demonstrate thermal image setters.

How make your artwork ready for printing and for positive output in correct manner.

How to convert low resolution file to high resolution and all about DPI, LPI & PPI

Complete workflow on screen making and screen reclaiming system.

So don’t forget to register online today:

29 – 30 Sept, 1 Oct 2015
Workshop on Advance Screen Printing Process on Graphics, UV Print Finishing, UV Special Effects & Packaging

27-28-29 Oct 2015
Workshop on Advance Textile Screen Printing Process, Special Effects on Garments & Heat Transfers

And get ready to Learn More | Earn More… at worlds most advance and finest institute DMI dedicated to the screen printing industry.

Have a pleasant weekend.

Bhargav Mistry

Don’t get caught by any Budget Analysis

Dear Friends,

Every year after the budget people discuss a lot about the pros and cons and so called experts give their opinion and advices but tell me frankly that from last 60 years the many poor has become richer, the richer have become super rich and in few cases richer have gone bankrupt. Was this due to any budget. Absolutely not.

Smart and clever businessman knows how to make money from any budget and situations.

So don’t get caught on budget and experts verdict remember one thing just innovate, innovate and keep innovating. Nothing will stop you from growing.

Have a successful year ahead.

Bhargav Mistry

Do not make ‘mess’ by using nylon mesh, use only polyester mesh!

February 6, 2013 Leave a comment

Because polyester mesh is best for high quality screen printing…

However screen printers need to do extensive R&D to unearth solution for their problems. However, to solve the registration miss–match problem, Polyester mesh is now being widely used. Polyester also has different grades. Polyester mesh is available in wide range from 6 mesh/cm to 180 Mesh/cm and various widths, in both white and yellow colours.

At excessive tension levels, the thread reaches to its plastic deformation point, and the screen will be stiff with no longer capacity to hold tension. However, it has been outshined by a new development in thread technology (High Module), which enables to bear the high tension with Low-Elongation for better and consistent print quality.

Polyester mesh is the preferred choice of the high end industries. i.e. electronics industry (PCB, membrane switches mfrs), CD printing, graphic printing, automotive decals, ceramic decals, tiles, glass, industrial labels, textile industry (garments and apparels, tag printing), Package Printing …even for halftone and fine printing like small micro letters, logos in a visiting card.

Features:
• High tensile and dyed fabric
• Low elongation
• No deformation of fabric
• Fast & good tensioning
• Quick lifting off fabric after squeegee lifts
• Fast ink release, Easy peel off
• Special fabric surface.
• Good Dimension stability
• Faster stabilisation
• Good durability
• Good resistance to acids & alkalis
• No water absorption

Benefits:
Ink savings: Low elongation means savings in ink, if it is used as per the specifications, instructions and right advice from suppliers.

Less consumption: It retains set tension level, print after print and job after job. This way, minimal distortion enables printers to obtain the most consistent results even after long printing runs. It not only improves productivity but also help reduce rejections.

High tension: Can be stretched to high tensions and maintain tension longer. Tension loss between stretching and printing is low and tension will remain stable over subsequent print runs. Higher tensions on press allow for lower off contact, which prolongs screen life and improves colour-to-colour registration accuracy. It also increases production speed.

Special Surface Treatment: Innovative mesh surface treatment provides improved wet ability and more uniform emulsion distribution. This treatment also ensure strong Adhesion: The mesh has an excellent screen making capabilities with outstanding resolution, resulting in a powerful adhesion to the photosensitive emulsion and tremendously increases the life of the mesh. The increased stencil adhesion properties firmly retain screen dots and fine lines, considerably lengthening stencil life.

Other benefits:
• Less choke up, less ghost image
• Easy to clean (after washing)
• Easy ink flow
• Consistent result
• Makes screen strong
• Preferred for good reproduction of minute details, sharp results
• Good for registration accuracy
• Good for high speed printing
• Increase in quality of job, improved registration due to stable tension
• Squeegee movement: silky and smooth
• High emulsion adhesion
• Stable printing dimensional accuracy
• Faster turnaround time from the screen room to the pressroom (Less tension change over time after tensioning)

Take care…

Bhargav Mistry

Role of advanced screen printing in packaging

September 8, 2010 7 comments

Hi Folks,

Recently I was invited by “Modern Packaging & Design Magazine” which is published by Infomedia 18 Limited to write an article on the role of advance screen printing in packaging as a guest columnist.

Many of you might have read my article if you are receiving their magazine, but if you have not read till now then here’s it…

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TECHNICAL ARTICLE, By Bhargav Mistry, MD, Grafica Flextronica & DMI
Published in Magazine “Modern Packaging & Design” Vol. 6, No. 1 | Jul-Aug 2010
(Copyrights remains with the publisher)

Screen printing process evolved over the years. Today, it offers ample innovation & creativity, thus playing a major role in packaging because of the availability of advanced screen printing machines, UV technology coupled with availability of innovative special effects inks.

Screen printing is a simple yet attractive process. The main reason is that in screen printing, the purpose and the art is to transfer something, almost anything more or less liquid through a screen!

It harnesses the natural phenomena of mechanical movement, flow and the interaction of liquids and solids. In screen printing, it is possible to attain controlled film thickness up to 300 micron. Besides, the printing medium – ink – can be almost any material that can be suspended in a fluid and which has a particle size that is ideally one third of a mesh opening.

Also, the visual impact that screen printing process can create is simply marvelous. The durability of the inks, the vibrancy of the colours, especially considering the harsh outdoor weather conditions for outdoor applications (sunlight, rain, snow, wind, etc) and its vast flexibility, all contribute to its unique capability. Screen printing is possible with any ‘semi-liquid’ product (various inks and dyes) on a number of rigid, semi rigid or soft substrates. Thus, these characteristics make it the most versatile printing process available.

Advantages of screen printing process

* High rub and scratch resistance, which is mainly required in industrial printing

* Vibrant colour

* Due to availability of high quality screen printing inks with better light fast pigments, 3-5 years of outdoor life for any kind of applications can be achieved

* Wide range of substrates of various thickness, size and shapes can be printed easily

* Good ink film and mechanical stability allows to screen print on complicated and rigid substrates.

* Knowledge and process calibration provides high dimensional stability

* Screen printing enables to achieve a degree of flexibility that is unavailable in other printing process

* Flexibility of short runs to large industrial volumes

* Inks are available as per application

* Possible to print on fragile matters

Advanced printing technology

Quality in screen printing seems to have come a long way. Today, with automatic precision machines, it is possible to get a result that years ago would have been a dream.  In the last decade, from a predominantly manual printing process there has been a big shift from manual operations to semi-automatic and NOW fully automatic printing machines. There are more numbers of screen printing machines sold today than it was five to ten years ago  because it not only involves low investment which is a big advantage for those wanting to join the screen printing business, there is also scope for creativity. The screen printing technology today is faster, better and cleaner.

Despite any type of screen printing press can be used (including manual and semi-automatic), the best press for that kind of work remains for me the cylinder press with automatic feeding, for reason quite often combination with offset, of speed, productivity and quality of result. And, for the same above reasons, the UV technology is also the best available one in the present and the future, both for technical and environmental reasons.

UV Curing depends upon the type of UV ink of varnish and of the thickness of the deposit: it is useful to know that in UV systems, a varnish even thick of several mm, will cure easily and instantly. For example, for metallic inks or some other printed chemicals, it have to be tested and set at very different speed and UV light intensity.

Complementary role

Screen-printing is a fantastic technology that is used by many industries with so many old, new and not yet discovered applications – both flat (plastics, cloth, metal, thin to thick papers, sunpack/sunboard, rubber, leather, wood, glass, ceramics, etc) and non-flat substrates, by using appropriate machinery and inks.  Further, this process is also widely used for printing packaging boxes, duplex and sapphire mono cartons, labels and cards, UV effect on packaging materials for cosmetics, toothpaste, jewellery … the list is endless.

Special effects!

In this world of shopping and mall culture, buyers are attracted by the packaging they can see and/or touch. Before that tryst with packaging, they also carry the memories of advertising (both print and electronic), outdoor posters, etc. As they walk into the shop, first they are also confronted with eye catching POPs and POS posters, placards and other marketing gimmicks. Ultimately, the packaging in a shelf carries its look, its power of attraction for the consumers, and eventually the feeling of touch, or we can rightly say, today packaging is all about sensation – look, touch, feel, smell.

So, special effect screen printing is a great way to excite consumers. The range and variety of effect is extensive and it provides the marketer, print buyer and designer with a number of exciting possibilities they may never have thought were viable.  This is because of the latest developments – machines and inks.

The most promising is the use of a wide range of ‘special effects’ thanks to the think tanks in the screen printing industry driven by FESPA, an international association of various national printing associations including India. FESPA spent a lot of resources to make a special book named “SENSATIONS” that shows many of those screen printed special effects.

The packaging can be printed through many techniques: offset, flexography, screen and digital printing or other. However, only screen printing allows to add those “special effects” enhancing the final product due to its versatility. These possibilities, combined with off set, digital, flexo or classical screen graphic, open a huge niche to many screen printers who will be able to offer customers truly enhanced and unique products and images to increase sales.

This is obtained by the addition of some surface effects that will catch one or several senses of consumers: The view or look of packaging which makes a initial difference – it is like first impression is the last impression … but now consumers want to touch by the feel of it and sometimes, why not rub and smell it. Amazing though, several of these effects can be used on the same item (multiple special effects, like we try at DMI institute). It can also replace, often at a lower cost, some other technologies such as hot stamping, doming, silvering under vacuum.

Specialty Inks & Varnish

The print buyers these days want something different from their competitors and are prepared to pay a fair price for that. They will accept a much higher price if the printers bring a very special enhancement of their product packaging image. So, one of the most interesting niches in the graphic screen printing fields is the printing of special effects, using UV special effect inks.

The inks available in the market range from luminescent to tactile, from glitter to mirror. The impact they can add to designs is breathtaking.  Screen printing effect can enhance any marketing campaign and may give it that extra competitive advantage. One may also enhance the effect with ink or an overprinted varnish. Varnishes have become a popular finish on wise labels especially because it gives the graphics a much greater richness of colour.

A gloss varnish over a matte surface is a more subtle approach that inspires curiosity. One sees a shape under the light or notices a smoother feel against a more resistant matte solid area. Similarly, coarse, high luster effects are created with thick coatings of varnishes that have large particle sizes. It is a striking way of printing reversed out images of icons or logos, an ice effect or extremely fine line patterns. A wrinkle effect can be created when a UV varnish is cured under UV-A light.

There are thermo-chromic inks. These are sensitive to temperature change and can be used for time temperature indicator labels. Irreversible ink types, which do not change back to the original colour, indicate if perishable goods have been stored for too long or at to warm a temperature.

Packaging for the blind

For blind people, the “Braille” texts on labels or packaging are printed. Here, a thick varnish screen printed is widely cheaper than micro-embossing through die-cutting or embossing technologies. Embossing is a slow and expensive technique (for the tool itself). It can be easily replaced by screen printing of thick UV varnishes.

Security

The security feature of screen printing is immense. This feature can be used to protect the brand against counterfeiting or tampering. RFID labels are used to provide security and efficient tracking and tracing of products, cases through the supply chain.

I have a customer of mine in Mumbai who is into packaging (with offset and screen printing unit) whose clients are happy that he offers something different every time because of UV special effects which they feel a luxury value addition especially in case of cosmetic, and such luxury product packaging. He strongly feels that UV special effects are not only luxury value addition for customers but a ‘safety net’ as well. Because of the very nature of special effects, it will help the companies in protecting their brands from duplication.

RFIDs

One fantastic application of screen printing is the printing of both antennas and transmitter/receiver in RFIDS : Radio Frequency Identification.  This is beginning to replace at short and medium term the classical barcodes that need to be caught at very short distance. The printing of those items, both on or inside of the packaging itself or on a special label to stick on or in, is ideally suited for screen printing in that sense that it is the best technology to print the conductive silver, carbon or nano-particle inks for the antennas or receptors.

‘Substitute substrates’

Continuous advancements and developments in polymer technology, expertise and cost-effective manufacturing, plastics is replacing traditional materials in many fields (environmental conditions apply!). These include : PVC, Polypropylene, HIPS, Lenticular Films, Polycarbonate etc. Polypropylene Sheets are extensively used for blister packaging, cardboard boxes etc. Polypropylene finds application in Disposable Containers,  Embossing, Gift Box Making out of clear sheets, Freight Packaging, etc. The trend these days is to use a substrate with a low density which also makes it affordable. PVC Sheets and Polypropylene Sheets are the best suited for screen printing. Polypropylene as a material is very eco-friendly and can be easily recycled. It is accepted and widely used all over the world for different applications. It is preferred by screen printers because of its low density and very economical cost. Similarly, PVC for screen printing purpose is a very good option. A good quality PVC sheet makes a good surface for a screen print because it has a pre-coating on it; even if the material gets old the coating is never hampered.

Perfect expertise needed

The main problem is of course the adjustments of registers, knowing, for example, in offset if each sheet printed simultaneously in four or six colours is perfectly registered, it can be some differences from one pallet to another. In case of UV spot effects, the register problem is crucial and requires a perfect control of the different elements of the image.

Some special effects will have to be entirely designed or separated from parts of the original image: this means that either a studio or an individual that created the image and/or yourself are able to prepare the needed proper part of the file: this is of course very important. In PDF, the problem of layers and transparencies can be difficult to solve: it also depends upon the quality of the files received from the customer or its studio.

As those effect will quite often have to be overprinted on inks and/or substrates printed with other technologies (offset, digital printing, flexo, hot-stamping, foils, etc.) a huge care must be taken. For example, even, for a simple high gloss spot varnish above a classical offset print on paper or board, be sure that the offset inks are over-printable: this means that they must not contains any wax, or worth, silicones, or of course that the so classical automatic powdering has been eliminated by the offset printer through a careful automatic brushing.

Patience please

Screen printing is now quicker, cheaper, produces better quality images and offers a number of special applications. But advanced screen printing with high level of automation is not everybody’s cup of tea. Having advanced machines in place is not sufficient to run a profitable screen printing business. There is no profit “from the press of a button” like in digital printing arena. There is no short cut. Because not only does the set-up process take considerably longer than other techniques, but being able to truly master printing high quality images using the screen printing process also takes much longer, because there are a number of variables involved.

Today, there exist different systems designed to help the screen printers to achieve better result. But it revolves around the simple concept or standardisation of the entire screen printing process.

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I hope you must have enjoyed reading…

Special regards,

Bhargav

14 point to become successful in printing

August 29, 2010 6 comments

Hi folks,

Received a nice SMS from one of my friend which had a good management lesson so I thought to share with you because most of the time we loose our temper for no reason. But now you got the solution.

A profound and breakthrough thought:
“If U can’t change the ‘Person’
Then
‘Change’ the person..!!

Also few important points to share with all my students because I am noticing this as a regular problem with all the new comers. So kindly read them carefully because these points may help you to be a successful person in life.

1. Take up printing as your profession only if you love it. It’s a grueling life and only one’s passion to become printer can overcome that. Remember that initially you may need to sacrifice quite a bit, especially your personal life.

2. Printing is nothing but fine art according to me. Printers, on other hand, is that much more. It is a way of life. You need to constantly look for new techniques, ideas and innovations.

3. A successful printer always prints for himself and for his satisfaction.

4. You need to maintain and sustain the efforts and results; and this requires years to resolve, dedication and hard work not just in printing but in every profession.

5. Talent does not matter much, yes frankly I believe that talent is overrated concept. You can cultivate your skills. Anyway, talent is not much use without the other ingredients – hard work, keeping oneself focused and staying motivated.

6. There are talented printers, there are hardworking printers, there are smart printer and there are printers who are great in getting access. However, it’s rare to find someone who possesses all these qualities.

7. Concentrate in quality rather getting quantity. Keep patience because that’s the key towards success.

8. Never get tired of failures, keep experimenting and develop new ideas.

9. Competition is healthy:
Once I was waking on a beach early morning all alone. I was assuming my waking speed was very fast unless someone overtook me.

Competition in business or amongst students is the same because it make you realize what you are and where you currently stand, competition alway strives you to deliver your best.

10. Academics are important:
Education helps you understand the basic of social behavior and also teaches how to write and talk, which is very important to launch a new career.

11. Experience is the best teacher
Read a lot. Develop a systematic reading habit in your life. But remember that experience is your best teacher, especially when it come to printing. You need to carve your own space in the organization, which happens only with time.

12. One should alway have some hobby in life. All successful person in life has one.

13. Adopt a GURU
It’s unfortunate that India does not have a history of printing education. To overcome this problem, I recommend you should assist someone. Your GURU will not only guide you and help you develop your skills, but also let you access high-end equipment.

14. If you respect your colleagues, seniors and customers, you will be respected by them.

So, relax and enjoy this beautiful rainy Sunday.

Good news and ideas are on the way so keep in touch.

Bhargav

Digital Printing & Proofing Tips

After returning from FESPA, Munich I just had couple of days left to prepare for my workshop at DMI. There after I had to finish my long new presentation for our unique road shows. These shows are organized by us (GRAFICA FLEXTRONICA) to launch our unique NANO PREMIER LEAGUE series in various every cities of India.

Till now with my team I completed 6 road shows, 3 in Maharashtra (Nashik, Aurangabad & Pune) & 3 in Gujarat (Surat, Ahmedabad & Rajkot). All shows were jam packed and very much interesting and had many uniqueness. I shall post full report with photos of my workshop and these road shows soon. Just to give an idea every city we had over 100 to 150 printers but Ahmedabad had a rocking figure 275 printers. Isn’t it amazing. Every where for me and for printer it was a WOW feeling.

In the mean time just enjoy this video tutorial from Dr. Russell Brown who is one of the chief engineer and scientist of ADOBE. In this tutorial he has cleared all doubts about digital printing and proofing.

Printers today gets digital proof either from their customer or they do it in-house using EPSON or HP digital printers for matching our screen prints.

So its important to understand the color management issues using analog vs digital technology.

Download these 2 videos which shall help you to generate correct proof using accurate printing parameters.

Printing to the Epson Stylus Pro 3800

Printing to the HP Photosmart Pro 9180

If you are on our database you shall soon receive our e-news. If you are not getting it regularly every month than make sure you register thru our website.

Have a cheerful and informative week.

Bhargav
00:50, 19th July 2010

Watch my educative film on screen printing process

Hi Folks,

First of all a happy rainy day. Now the time has come to beat the heat because this morning the grass was wet with dew. Finally mumbai is blessed with rains.

Every saturday I usually work late night 3 to 4 midnight and sometimes even on sunday afternoon because next day its relaxing day with no phones and not obliged to reply any emails…

Today at home, relaxing this evening and working on my ambitious project, revamping my technical slides which I was presenting in my workshops till now. Anyway I have to finish soon before my next workshop which is scheduled from 1 to 3 July 2010.

In my new presentation I would like to incorporate all my recent and past experiments with many new ideas. Even though I conduct live workshops but still I would like to include many (HOW TO) video illustrations of each process in screen printing step-by-step.

GREAT NEWS!!!

On 12th June 2010 in mumbai I would be presenting my FILM “SCREEN-ON-SCREEN” which is an Educative Film on screen printing process. This event is organized by Screen Printers Association of India (SPAI).

In this film you will see right from screen preparation to screen printing all with advance techniques using latest equipments. This film reveals all secrets about advance screen printing process and it took me more than three months to complete this entire 1.5 hour long film.

Last year my company organized 15 road shows all over India and more than 1200 printers till now enjoyed watching my unique film. So its a great chance for you to watch my FILM in Mumbai, the only city I have not screened yet. I invite all of you to come and educate the latest techniques in screen printing.

Don’t forget registration is very much compulsory so come prepared.

Download Registration Form if you wish to participate.

ROAD SHOWS!!!

Grafica’s NANO-PREMIER LEAGUE is set to kick start nationwide road show starting this month.

NANO PREMIER LEAGUE (NPL), is a complete in-house screen printing solution offered by my company to give complete freedom to screen printers.

The first show will begin from Nashik 17-Jun-10, followed by Aurangabad on 18-Jun10 and finally at Pune on 19-Jun-10.

I will be presenting the features and advantages of all machines combined in NPL package plus a presentation behind making of NPL.

There will be technical/commercial disclosures for printer who wants to decide on the spot to purchase our NPL super saver combination package. Also there will be a special discount only on that particular day for those who wish to book on the same day.

If you are planning to go for automation this is a right beginning. So come duly prepared to get an exclusive offers from me on that day.

Also there will be live demo of these wonderful inventions of Grafica and a huge sample gallery will be kept for display to see all latest DMI’s creations in process color screen printing (100 LPI), print finishing, wedding cards, paper carry bags, chocolate box and packaging. A unique folder having 16 different special effects will be hand over to everyone present on that day. This shall help screen printers to get more creative ideas.

The admission is free, however, entry is strictly by registration for printers only.

Download registration form

Checkout more information on my companies website and on our recent GraficaNews and stay updated.

Have a showering week.

Bhargav

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