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Spot Process Colour Separation for t-shirt screen printing

AVOID CMYK SCREEN PRINTING ON T-SHIRT & GARMENT.

Use the latest spot process colour separation technique to achieve high-quality photo images on t-shirts and garment.

Download FREE high-resolution sample files to learn. You can also output positives using the sample files to see the difference in print quality.

Part – 1

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टी-शर्ट और परिधान पर सीएमवाइके स्क्रीनिंग का उपयोग न करें।

स्पॉट प्रक्रिया रंग पृथक्करण तकनीक का उपयोग करके टी-शर्ट पर स्क्रीन प्रिंटिंग प्रक्रिया द्वारा फोटो गुणवत्ता छवि को कैसे प्राप्त करें.

सीखने के लिए मुफ्त उच्च-रिज़ॉल्यूशन नमूना फ़ाइलें डाउनलोड करें। आप प्रिंट की गुणवत्ता में अंतर देखने के लिए नमूना फ़ाइलों का उपयोग करके सकारात्मक भी आउटपुट कर सकते हैं।

भाग – पहला

DOWNLOAD FILE LINK

https://www.dropbox.com/s/t2mfznvtnmzk2k4/Miami_Glow_CMYK.psd?dl=0

https://www.dropbox.com/s/pinhqiyrojmrft5/Miami_Glow_Separation.psd?dl=0

Learn FM Screening to get Moire Free Prints & Achieve Digital Like Quality by Screen Printing

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In all my future workshops at DMI on textile screen printing you can now learn in depth about high definition screen printing process using 2nd Generation FM Screening technique to print DIGITAL like quality by SCREEN PRINTING process.

DMI is the first and only institute in the WORLD teaching latest and advance screen printing process in graphics and textile field and demonstrating the state of art high definition screen printing on textile using 2nd generation FM screening live and practical for free.

DMI is the only institute in the world teaching, graphics, industrial, print finishing, value addition and textile screen printing for free under one roof.

In all my workshops I teach right from designing to pre-press to colour management to screen making, screen printing, post-press live and practical all three days.

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Left Side Image (AM Screening) – Right Side Image (2nd Generation FM Screening)

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On 5th June 2015 during our grand re-opening of DMI institute in our new premises. I had made a statement in front of 100’s of printers who were present there, that “Once upon a time there was a moire problem in screen printing… what I meant was that moire will be a history in screen printing industry from now onwards. Yes at DMI we successfully implemented it and have also started conducting workshops and training programs on this subject.

So, MOIRE is no more a problem in screen printing with 2nd Generation FM Screening Technique.

After years of research and development in screen printing at DMI I have completely discarded AM screening in all my courses. Now I am only focusing on 2nd Generation FM Screening techniques which produces digital like quality through traditional screen printing process in graphics and textiles.

dmi_textile_workshop

Moreover the advantage of using 2nd generation FM screening is to avoid moire in screen printing. Especially when printing halftones on garment it becomes very difficult to control moire even after using coarser halftone dots like 45 LPI.

2nd generation FM screening totally eliminates moire in screen printing thus delivers sharp, crispy and brighter images. Even finer and smaller details are clearly visible.

FM_Screening-1

Left Side Image (AM Screening) – Right Side Image (2nd Generation FM Screening)

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To take one step further in the implementation of the 2nd generation FM screening in your company. I have made some test files which you can download and print at your end to check and compare the results of 2nd Generation FM screening vs conventional AM screening.

Email to: dtg@graficaindia.com or call us on our helpline number +91 8 655 755 855 so that we can send you the link to download DMI’s complete “Step-By-Step Instruction Guide”. This guide also explains how to print 2nd generation FM Screening to produce digital like quality through screen printing process.

Along with the instruction guide I have included many TEST FILES in PDF Format ready for positive output on any imagesetter. So once you download the test files, you can again call us on our helpline number for further guidance.

At DMI, Learn More – Earn More and be innovative.

Bhargav Mistry

Attention Garment Screen Printers, Are you making profit or just surviving?

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I am writing this blog to educate all garment screen printers with regard to the factors which influences costing. And after going through these points one can correct themselves to avoid further loss in business.

It’s difficult to educate or inform everyone, on one to one. So I thought the best way is to write this blog so that everyone can read, understand and implement these points before quoting for your customers job.

As garment screen printers you should never forget that you are helping your customers to sell their printed garments and because of your quality and services they are able to sell their garments in the market effectively.

Majority of garment screen printers, mainly into job work, only consider ink cost and add ‘margins’ with an understanding that the so called ‘margin’ covers their direct and indirect costs. It’s surely a blind faith!

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I have been conducting workshop and seminars in my institute DMI since 2006. In this 10 successful year I have been teaching advance screen printing process on latest machine and equipments using high quality materials and consumables.

During my 3-day workshops, screen printers sincerely write down all the methods and processes that are explained in my theory and practical sessions, and they even take photographs, probably to implement in toto what I teach. But back in their print shop, they seem to be hesitating to use the same method, products or similar quality materials like inks, emulsions, screen mesh, squeegee rubber etc, just because they find it ‘expensive’ compare to what they currently use. And, the end result: they fail to emulate the kind of quality that we have demonstrated in the workshop.

Frankly, the materials are not that expensive but printers are compelled to use lower standard materials and consumables because of their wrong costing and pricing structure prevalent in the market.

Most of the screen printers in textile and garment sector, especially engaged in job work only considers INK as their major cost while making their price-list per colour basis but they totally forget so many important factors during their calculations before sending quotations to customers.

To begin with, for the time being keep the cost of ink, emulsion, screen mesh out from your mind for a while because if you are not taking into account the following things while quoting your customer than I am seriously concerned whether you are making profit or just surviving in your business?

  1. Designing
  2. Positives
  3. Screen making
  4. Rejections
  5. Ink wastage
  6. Squeegee rubber & its maintenance
  7. Electricity charges per piece
  8. Labour
  9. Overtime
  10. Plant & Machinery
  11. Machine maintenance / AM
  12. Spare parts for plant and machinery
  13. Administration & office expenses
  14. Sampling
  15. Other overheads etc…

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DESIGNING:

Even if you have your own art department and artists to do designing, that doesn’t mean it’s not costing you money. Whether the lot size is bigger or smaller, design charges should be added in the costing. Be cautious that if designing charges are not taken from customers as a matter of regular practice, then you as screen printers end up struggling to purchase high quality designs or hire professional designers. But if you start charging for designs, you will not hesitate to purchase high quality designs from professionals or other online paid source, and hire experienced / professional designers for your pre-press activities.

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POSITIVE:

Majority of screen printers in garment/textile sector use tracing paper (generally knowns as ‘butter’ paper) and output their positives on desktop laser printer. It’s because customers don’t pay so printers try to save on designing and positive making and finally struggle for getting good quality printing. Even I have noticed that inkjet films are also considered ‘costly’. Hence image setter positives are out of question.

So always charge to customer for designing as well as positive making especially for smaller lot size.

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SCREEN MAKING:

Screen is the heart of screen printing. I always mention in my workshops ‘Good Screens = Good Quality Prints’. Believe me screens plays the major role in the quality of printing and many screen printers don’t have any idea what should be the right quality of screens. Textile screen printers main focus is alway ‘automatic machine’. But I would like to remind printers once again that to achieve 100% QUALITY in garment screen printing,

Designing & Positives (Pre-press) has 40% role
Screen Making – 40%
Automatic Machine – 10%
Inks & Consumables – 10% Provided if you are using high quality materials and consumables from renowned companies

The reason why screen printers end up making poor quality screens is because they don’t charge their customers for screen making nor they add it in their pricing based on the lot size. Hence they are compelled to use substandard positives, screen mesh, emulsions, chemicals and unprofessional way to develop screens.

Screens are not FREE it cost you lot of money and also does not last longer so it should be charged to customers separately.

The life of screens for printing photographic images with water base inks using fine halftone dots last only upto 500 to 700 impression. If you are lucky or if you have not cleaned the screens in between production due to ink choking or during any intervals etc. than it can deliver upto or over 1000 impression.

POOR INK & EMULSION QUALITY reduces your screen life so use the best mesh, emulsions, chemicals and inks. The life of the screen especially in halftone printing majorly depends on ink so use high quality inks which reduces ink choking issues thus eliminates screen cleaning during production thus avoids stencil wear & tear.

The life of screen can sometimes double or even more with PVC free-phthalate free plastisol inks compare to conventional water based because these plastisol inks does not choke up in screens and does not require cleaning in intervals. But nowadays many companies makes very high quality low-choking water base inks which can also eliminate screen cleaning during production thus increases the life of the screens.

The screen making charges also depend on the number of colours and type of screen required for printing. E.g. the cost of high density screen should be charged higher compare to conventional screen making because it take more time with special attention and care plus the cost of thick film is also higher compare to conventional emulsions.

And don’t forget that screens do have limited life, sometimes it tears due to poor handling or during printing due to dust particles in ink. So in a month some amount of new screen mesh has to be considered in your costing.

DMI_Workshop_20150824-136

MACHINE SETUP:

Most of the job workers (garment printers) complain that their lot size has now shrunk between 300 and 500 pieces per lot.

So, in this case it would be the biggest blunder or loss making, if you are not charging or considering the cost of machine setup. Everyone knows ‘job changeover’ time is the biggest nightmare in garment printing.

According to me, on an average, the time taken by screen printers practically to change from one job to another is around 1 to 2 hours, or sometimes even more depending on number of colours and accuracy of the job.

If a company runs 8-hour shift (which never happens practically you know!) they end up with average 6.5 or 7 hours a shift. In that case average only 3.5 lots can be finished per shift, considering a min. order of 300 or max. 500 piece per hour considering 1 hour spent for job changeover and setup in between.

So, if you do not charge/consider ‘job changeover’ time and ‘machine setup’ time for smaller lots, then even survival would be difficult, forget about making profit. Because most of your ‘profits’ are being leaked out incognito due to time lost in job change over and machine set up.

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REJECTION:

Many printers are least bothered about the kind of wastage and rejections. Of course, not all pieces are perfect in any production process. Their bound to be rejections which have to be taken into account.

If customer sends job for printing and if they deduct any amount from your invoice due to rejection then you should inform your customer to send you extra pieces needed to cover up the tests, trials, wastage and rejections. You should inform them in advance that there would be certain amount of rejections in each lot and they should accept this fact and should not deduct any amount from your bill.

These days companies are spending millions in process standardisation and process control to minimise rejections. But many average screen printer do not even have weighing scale to weigh ink for repeat accuracy or any meter to make special colour match inks in-house etc. so they all go by an ‘approximate’ measurement done by naked eye and judgment. So, compelling screen printers to have a rejection percentage in ‘points’ in current situation is not practical.

According to the current circumstances & situation 15% to 20% rejection should be considered acceptable for an average screen printer who does have modern setup or right kind of skilled people with proper knowledge and process standardisation.

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INK WASTAGE:

If anyone claims that they do not incur any wastage of ink, it’s totally wrong. Whether you print 100 or 1000 pieces, there will be some amount of ink wastage, especially when printing with water based inks.

The wastage is higher in water based inks compare to PVC free – phthalate free plastisol inks. The advantage of PVC free – phthalate free plastisol inks is that after each job, you can recover every drop of ink back using sharp spatula (except some ink residues left on screens) and secondly the ink does not dry in the screens and there is no evaporation like water based inks.

So, if you are printing with water base inks 15% to 20% wastage of inks should be considered in your costing. This wastage includes the ink you leave on sides of screen and which gets thicker/harder after some time due to water evaporation. In some extreme conditions wastage cannot be reused.

The major factor of water based ink wastage is due to higher temperature in some countries and places plus mainly due to poor plant conditions.

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SQUEEGEE RUBBER & MAINTAINENCE:

The last priority item for every screen printer is ‘SQUEEGEE RUBBER’.

Printers never pay attention to squeegee which is the most crucial tool in the management of quality in printing.

Most screen printers may expect that the squeegee supplied with the machine, should last for years and years! Even the maintenance of the squeegees are so bad and they are never sharpened.

I have seen printing companies where they use squeegee for years unsharpened! Printers should understand that squeegee life is limited and its hardness starts diminishing from the original count (strength). At DMI we change squeegee after its hardness is diminished or if the length reduces more than 5 mm after frequent sharpening.

Even good quality sharpened squeegees can reduce your ink consumption by 5% to 10% in some extreme cases.

Please be aware that the squeegee has a limited life, and hence it should be replaced based on certain ‘weakening’ criteria. So, printers using automatic machines should consider the cost of squeegee while working on costing.

ELECTRICITY CHARGES / LABOUR CHARGES / OVERTIME CHARGES:

Many printers do consider electrical & labour cost but just for a rough estimate.

But the cost is not added on ‘per piece’ basis, because the electrical & labour charges will completely depend on the lot size. E.g. the cost of electricity & labour to print 100 or 10,000 piece will remain the same, but it will change drastically based on the lot size due to change over time, downtime, wastage of materials, and time wasted by labours during job change over. In this case the price cannot be the same per colour for 100, 300 and 1000 or more…

So, electricity, labour cost and overtime charges very much depends on the lot size, setup time and change over time.

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PLANT & MACHINERY / MAINTAINENCE CHARGES / SPARE PARTS:

Your plant and machinery requires regular maintenance. So if you cannot generate enough profit you will have to compromise on the maintenance of your plant and machinery which indirectly reduces the life of your machines and thus it will affect production and quality.

Better to deposit some amount every month in a separate account for safety and for maintenance of your plant and machinery like machines, generator, vehicles etc.

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ADMINISTRATION COST:

Your office administration cost in general should also be considered based on your monthly production.

E.g. If 10 people are working in your office for admin work with an average salary e.g. Rs. 15,000 per month, and let say your monthly production is around 100,000/per month and you have already added Rs. 1.50 in your costing. Now if your quantity shrinks down due to change over time or ink matching time or for any other reason, then it will directly affect your profit margin. But if you increase your production and productivity with same people, your profit will increase drastically.

FINALLY, FREE SAMPLING:

I know there is a trend all over to provide free samples to customers.

But I do not want to explain in details because by now you must have understood why one should not make free samples to customers. Because it cost you a lot of money for making screens, positives, setup time and other overheads.

While making samples for customer, you have to make special match colours. If the design works, you consume those inks; but if the design fails, your matched ink has to be used in other jobs or it remains in stock and has to thrown after some time.

That’s the reason why DMI has introduced a new system where in you only have to keep stocks of basic 14 Pantone colours, and all your designs will be printed using those limited colours. This will help you to minimise unwanted stock of inks and time to match special colour. Quite often, while matching special colours, there is possibility of wastage due to error in colour matching.

So, it’s not only the ink cost that you need to consider to add to your profit, but all the above factors should also be considered while working on your costing because today the major cost is labour, electricity, land, machinery and overheads.

Don’t struggle in production by using substandard, low quality inks, materials and consumables.

According to me don’t consider INK or EMULSION cost into your mind, if you increase your productivity, reduce machine setup time, reduce job change over time, minimise colour by doing proper separation of each designs believe me INK or EMULSION cost will be no where in account.

Most screen printers works so hard, spend so much time and energy to source cheaper substandard inks but fails to understand that the ink, emulsion cost even does not come into account if you increase productivity, reduce rejection & downtime, reduce setup & job changeover time. Don’t forget day by day overhead, labour cost land, electricity etc. will become very expensive compare to INKS & EMULSIONS.

Based on my experience and observation, I urge all the garment screen printers…

“Do not consider the costs that you feel to be considered and do consider the costs that you feel should not be considered”

So avoid further loss and start charging your customers for designing, screen making, positives, sampling and development charges on regular basis.

Because its better to maintain healthy competitions for long term business and don’t let your customers take the advantage of your ignorance & innocence.

To be more productive, reduce machine setup time, reduce job change over time, minimise colour & screens using high end colour separation software and to understand costing in details register to my workshop on advanced screen printing on textile.

For more information log on to: www.graficaindia.com

Be profitable and remain healthy in business.

Have a profitable week…

Bhargav Mistry

 

Upcoming Events & ITMA 2015 Update

December 6, 2015 Leave a comment

Hi Friends,

There are many events at Grafica and DMI in a row this month.

After I returned from the ITMA’15, a mega exhibition related to textile/garment industry held on 12-19 November 2015 in Milan, Italy. As an Indian distributor of Aeoon Technologies, Austria, we also shared a common platform with Aeoon to promote Aeoon KYO series digital printers in India.

Aeoon Direct to Garment Digital Printing Machine

Aeoon @ITMA 2015, Milan, Italy

Aeoon’s young and super sturdy machines have really rocked and proved their strength in the global market by securing several order bookings at ITMA.

This shows that despite the severe competition, their machine is one of the finest in the world. I came to know that some of their customers were using other DTG digital printing machines, but they were quite disappointed in terms of quality and productivity, hence they turned to Aeoon. That’s really amazing.

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Aeoon’s few World Wide Distributors

The success of Aeoon Technologies is purely on merits of – Quality of their machine, striking design, productive features, performance and higher customer satisfaction. I would say the credit for Aeoon’s success should also go to their network of loyal dealers/ distributors and of course Aeoon management’s trust and confidence in them … I feel for a manufacturing companies like us, gaining dealer’s and customers’ loyalty and trust is very important for the growth and success in business and Aeoon has proved to be the best company to satisfy their dealers and distributors.

CLICK HERE TO SEE THE PHOTO GALLERY

Anyway, back home, our team is just getting ready for the PAMEX’15 exhibition to be held in Mumbai on 9-12 December 2015. We will be showcasing our Cylinder Press, and other semi automatic screen printing machines. Our team will hold constant live demo to reveal the secret of value addition. I and our team expect to meet many of you at this mega event held once in two years.

Grafica@Pamex2015

After this exhibition, my team will rush to exhibit our nano-prinTex and nano-prinTag at KnitVision in Ludhiana on 18-21 December 2015.

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Grafica’s New nano-prinTex 18 Pallet, Automatic Direct to Garment Screen Printing Machine. Available with max. print area 28″ x 40″

And on the export front, our Turkey distributor, Fatih Tekstil, is gearing up for the FESPA- EURASIA to be held in Istanbul, on 10-13 December 2015.

Available from 1 to 4 Colour print heads with Flash between each print heads for superior quality printing.

Grafica’s NEW nano-prinTag plus Available from 1 to 4 Colour print heads with Flash between each print heads for superior quality printing. Max. Print Area 12″ x 14″

Meanwhile, I know that many of you in garment industry couldn’t attend DMI’s recent workshop on Advanced Textile Screen Printing Process. So, we share the glimpses of 3-day workshop held on 27-29 October 2015 (Page 6) of our latest Grafica News India magazine November 2015 issue.

Finally, please join me in congratulating 4 companies – PRS Permacel, Tarun Print Tech, Classic Stripes, and Nageen Prakashan – who, in all, won as many as 25 awards in the recently concluded SGIA’15 competition in USA, making India proud. (Page 12). And, now that Fespa has also invited entries for their 2016 Award Competition (Page 12) of our latest Grafica News India magazine November 2015 issue.

Glimpses of my previous 3-day workshop on ‘Advanced Screen Printing Process’ (Textile / Garment / Heat Transfers) 27-29 October 2015 at DMI. The workshop was attended by around 35 professionals from garment industry.

DMI WORKSHOP PHOTO GALLERY 27-28-29 OCT 2015

And finally my upcoming workshop on direct to garment screen printing is scheduled on 1-2-3 Feb 2016. So if you wish to learn DMI’s latest innovation on garments to print Digital like quality through screen printing to reproduce nearly continuous tone images than kindly log on to www.graficaindia.com and reserve your seats today.

Here is the video showing our recently printing images using this new technique.

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YouTube Video Link

If you wish to get our 10 latest samples printed using this technique for FREE then call our sales team on +91 22 26838815 / 6

Thanks and have a great Sunday.

Bhargav Mistry

Few tips to bring change in the screen printing industry

February 6, 2013 1 comment

Here are some ‘New Year Resolutions’. I am sure the industry will see “A BIG CHANGE” if these ‘Resolutions’ are followed.

Here we go…
1. Adopt automation to improve productivity.
2. Pay attention towards value addition whether its graphics or garments because that’s where the profit lies.
3. Screen is the heart of printing, so do not compromise on screen making equipment, emulsions, mesh & chemicals.
4. Use only polyurethane squeegee rubbers and sharpen the edge regularly to decrease ink consumption.
5. Maximise the use of UV Inks where ever possible (for graphics, industrial and commercial screen printers).
6. Maximise the use of Water Based Inks, PVC FREE – Phthalate Free Plastisol Inks (for garment screen printers)
7. Use only Yellow Polyester Mesh of high quality.
8. For halftone screen printing use dual-cure photopolymers emulsions and for better sharpness and quick exposure use SBQ photopolymer emulsions.
9. STOP wooden frames and use only aluminium frames
10. Work towards standardisation.
11. Pay attention to avoid. rejections and reduce wastage
12. Spend money for education and training.
13. Visit all printing related exhibitions to keep pace with the latest trends & technology.
14. Have concern for environment, safety, energy savings and other cost saving measures.

My message to screen printers who are into job work:
* Pay more attention towards quality and productivity and do not buy cheaper and substandard raw materials, because today labour, electricity and overheads are more expensive than those cheaper raw materials. Purchase raw materials and develop vendors/supplier who can provide better service and knowledge.

My message to all garment manufacturers who are having in-house printing unit:
* Use only high quality inks and forget ink cost, because the ratio of ink cost is very negligible considering the entire production cost of garment, even if you buy the most expensive ink. Because print sells…

Remember, to bring change in the industry, we need to change.

Bhargav

Nano-PrinTex is now being “marketed” by our competitors!!

December 23, 2012 2 comments

Hi friends,

Being in the manufacturing of flat-bed screen printing machines, cylinder press, fully automatic flat-bed machines and allied products for more than two decades my company Grafica had never experienced success the way we are experiencing since the day we launched the world’s first all electrical mechanical automatic direct-to-garment screen printing machine “nano-prinTex”. And the credit goes to one of our close competitors who are a distributor of a foreign company selling similar kind of machines, inks and consumables to textile screen printers in India.

I must “sincerely” thank them for their continued negative promotion/marketing which is directly helping us to sell our nano-prinTex easily and effort less, although their motive was otherwise!!

Here a recent case study of our victory in a trade exhibition:
A reputed garment manufacturer who placed an immediate order of nano-PrinTex without much introduction from our sales person happen to mention that when he was at one of our competitors booth he simply requested the owner of the company to clarify the technical difference between their product with Grafica’s nano-prinTex.

“But instead of explaining me the technical differences he kept on speaking only bad about your company and your products. Surprisingly what I noticed that he forgot my question and during the discussion I could clearly sense the kind of fear they have from Grafica. Their fear revealed the strength of your product as a result of which I made my decision clearly to buy Grafica’s nano-prinTex.”

These kind of cases are rare but from the day we have started manufacturing carousel screen printing machines for t-shirts printing, this competitor of ours have gone absolutely mad and crazy. In fact what I can see in them is fear, fear of losing the monopoly in the textile industry. In fact it is merely because of their monopoly customer had to buy their machines as there was no qualitative alternative!

So I would like to thank my competitors and their team for talking negative about us, sabotaging our image and making false stories about our products. By their constant and rigorous efforts in spreading negative news about Grafica’s nano-PrinTex we are gaining huge success in the textile industry. Also due to their wrong publicity our customers are gaining more confidence in our product and our company.

In fact our competitors are forgetting that Grafica is a manufacturer having a strong engineering team and prompt service backup. Today we have more than 2500+ customers with a solid network of dealers and distributors all over the world. Apart from prompt after sales and service support we also run a highly professional in-house training institute “DMI”. So far this institute has offered FREE training in screen printing to more than 1200+ students and printing professionals.

I think our competitor has wrong belief that customers are fools. But I strongly believe customers are smart, intelligent and clever.

For the success of Grafica’s nano-PrinTex, I wish their childish approach, unethical behaviour and unprofessionalism should continue forever because we are gaining more popularity.

Bhargav

Grafica’s nano-prinTex @ SGIA 2012 Las Vegas

October 15, 2012 4 comments

After a successful launching of Grafica’s nano-prinTex, worlds first all electrical mechanical automatic direct-to-garment screen printing machine in India & UAE my team is now moving forward to launch nano-prinTex at SGIA 2012, Las Vegas, USA between 18 to 20 October.

SGIA is one of the renowned exhibition in USA which is organised every year and is mainly focused on screen and digital printing. In this exhibition we shall demonstrate for the first time Grafica’s nano-prinTex live all three days.

Today, I am very proud to say that Grafica will be the first Indian company to participate in SGIA consecutively for 2 years demonstrating high quality screen printing machines and allied products. Actually this will be our third exhibition in USA (twice in SGIA and once in FESPA AMERICA)

Our North American distributor RH Solutions, Ron Hayden and his team is very excited and enthusiastic to demonstrate Grafica’s state of the art direct-to-garment textile screen printing machine nano-prinTex in SGIA 2012.

I also look forward to see my friends and colleagues from this industry and many ASPT members (Academy of Screen Printing Technology)

One the way to Las Vegas…

Shall update you soon about the show with lots of interesting photos covering the whole event.

Have a great week…

Bhargav

Grafica’s nano-prinTex LIVE DEMO Centre now in Tirupur

September 24, 2012 2 comments

Today I am proud to announce our new DEMO CENTRE in Tirupur.

Mysteries of textile screen printers in India

After my long technical vacation I am back with full confidence and enthusiasm to share some of my insights, views and opinions about the direct-to-garment screen printing industry which I experienced from my last workshop and our companies participation in two exhibitions – GTE 12, New Delhi and KnitWorld, Ludhiana.

GTE 12 - New Delhi

GTE 12 – New Delhi

Knit World - Ludhiana

Knit World – Ludhiana

But first I would start from where I left…

THE LAUNCH PARTY…

The launching of Grafica’s nano-prinTex was a full house with more than 150 invitees from garment screen printing industry across India …

The event began with my welcome speech, product presentation, live demo followed by cocktail-dinner. Apart from textile screen printers I had also invited DMI’s Sponsors, our dealers and distributors, industry associates and existing Grafica customers. I was really thankful to all those who attended this event and a special thanks to all our distributors, dealers for their supports. My special thanks to DMI’s sponsors (Sericol, Skyscreen, Colors, Technova, Adobe & Indian Dyes and Sales Corporation).

Upon my request Anil Brahmbhatt (Skyscreen), Raghav Rao (Sericol), Mustafa Kapadia (Colors) and Jayesh Shah (IDSC) openly shared the kind of benefits they are deriving from sponsoring their products and services to DMI.

After my presentation live demonstration of nano-prinTex was arranged in the factory…

Following the launch of nano-prinTex, we were flooded with requests from many garment screen printers to conduct an exclusive workshop on direct-to-garment textile screen printing. I was eager to announce my first 3-day workshop on direct-to-garment screen printing at DMI. Finally this workshop was successfully concluded on 5,6, 7 April 2012. Due to this unexpected scheduling of the workshop, I really had very limited time because there was too much of reading and meeting with experts, garment screen printers, ink suppliers to understand what sort of difficulties each one is facing related to their products and services so that all those issues could be covered in my theory and practical.

Screen printing is not a new subject for me but refreshing my knowledge in textile printing within a very short time was a big challenge. In fact my experience and knowledge in screen printing began with Industrial screen printing and thereafter I learnt many new tricks of process color graphics screen printing. That’s the reason why I found textile screen printing too easy for me to understand, because the only technology which changes apart from artwork, screen making and press parameters was inks and substrates i.e. fabrics. So my main focus all the time was to spend most of my time in understanding the chemistry of inks and the behavior of inks on the fabrics. I spend most of my time in DMI to standardize the process of inks, mesh count and press parameters to achieve consistent result.

Considering the high level of quality standards required in Industrial screen printing (e.g. PCB’s, Automotive Decals & Dials, Graphic overlays, Membrane keys, Glass and Ceramics etc.) and even in process colors graphics, especially in areas like screen making, pre-press and screen printing is much challenging and different in these segments as compared to garments / textile screen printing. That’s the reason why I do not compromise on printing quality.

In the last two exhibitions and in my first workshop I was surprised to hear from many big players in textile printing that they are not aware about the mesh count they use nor they knew anything about types of fabrics like Nylon or Polyester. When I asked them what mesh count they use few of them replied by saying 18 no. mesh or 20 no. mesh. When I explained that we use 77T or 90T or 120T they were confused???… Even when I asked the same question in my first exclusive textile workshop, the same answers came from the participants albeit with same confusion about mesh.

 

And, Dual-Cure Photopolymer emulsion remains a mystery… :
If I compare the level of understanding about emulsions, mesh count etc. between graphics / Industrial screen printing with textile screen printer, I personally feel that percentagewise, garment screen printers have less knowledge and understanding about screen making compare to industrial and graphics screen printers. I was really concerned that many printers use butter paper (tracing paper) to make positives in A3 size for a 12 color job. Often, few so called ‘intelligent garment printers’ ask me about the registration accuracy of nano-prinTex and my answer to them was to first check the accuracy of your positives with each colors before you want to know the accuracy… Butter paper hhmm..

 

This clearly makes me understand that at DMI, I have to focus more on screen making parameters to explain the importance of screen than just printing. Because the screen is the heart of screen printing, GOOD SCREEN = GOOD PRINTING.

World’s first exclusive workshop for 3 days on garment screen printing…
Complete new slides with new contents, theory and practicals. All new pre-press parameters and screen making techniques…quite challenging but was easy due to our years’ of experience and expertise.

   

On the first day I completely spent on pre-press, process color screen printing, artwork, separation techniques, positive linearization and press linearization techniques, and on second day I focused on Spot Process Techniques printing on white and dark garment. On the last day we printed with Special effects and water based inks on dark using metallic, glitter, puff, high density etc…

Participants:
This time we had couple of participants from nearby countries like Nepal, Bangladesh and many far distant places across India. To me one of the interesting participants who came all the way from Ludhiana was Mr. Ashok Jain of Miniking Knitwears Pvt. Ltd., one of the biggest and reputed garment manufacturers in the northern region. He came along with his son and two of his key production people. Being an owner he showed keen interest and enthusiasm to learn various techniques we demonstrated at DMI all three days. Very few owners like him take interest to learn technology with so much patience and very few owners send their people to learn. Most of them are afraid of teaching or sending their people outside to learn. Such printers have very conservative approach towards growth. I think teaching and training is an ongoing process and should be taken in a broader prospective if companies want grow their business. Towards this objective, Mr. Ashok Jain’s approach was very much positive because he told me that, “the company is being run by people and everyone in the company should be aware of the right process and technology to progress and it’s they who handle day to day problems and what I want is results”.

Like him there were many CEO’s, MD’s from reputed companies who took keen interest by participating in my workshop.

But, I urge all CEO’s, Owners, MD’s in garment/garment screen printing industry to also send their printers, managers, supervisors, graphic designers to DMI to learn correct process so that they can deliver quality output and you can reduce your day to day involvement in production and quality issues.

I remember that from the moment we announced our first workshop, within 15 days it was houseful. There were many wait listed participants who will get the chance for the next workshop. This shows the eagerness of textile screen printers. I wonder why there is not many institutes like DMI in the world to teach proper technology in screen printing.

I have incorporated many new and improved contents based on my first experience and requirements of screen printers at large. This time we will be screen printing process color using plastisol and water based inks. We also plan to demonstrate discharge ink on dark garments and special effects using water based and plastisol inks. Inks like metallics and glitters will also be included in few designs to demonstrate how to make attractive garments.

DMI Sponsors…
DMI sponsors have always shown their keen interest to support all my workshops but this time I would like to specially thank Jayesh Shah of IDSC, Raghav Rao of SERICOL & Mr. Konkane & Mr. Kamat of PIDILITE. In fact Mr. Kamat was keen to deliver his technical presentation on water based ink, pigments and on green environment. IDSC have supplied all plastisol inks for Spot Process on dark garments and SERICOL have supplied PVC-PHTHALATE free Plastisol Inks, Water Based Process Color Inks. PIDILITE have supplied their water based medium, binder and various pigments to make our own colors and some special discharge pigments to demonstrate discharge printing. They also included one magical water based ink which can be directly printed on any dark garments without under base white or discharge, still it can achieve bright colors.

In our next workshop we will refine our technique with great improvements to get the best result out of all these varieties of inks and chemicals.

DMI Students…
I specially thank all my students and DMI faculty members who worked day and night with me. These boys were so curious and enthusiastic. That’s the reason why I could also work non-stop along with them without getting tired.

There are many surprises for garment printers coming soon…

So be in touch with us. After my second textile workshop which is scheduled on 17-18-19 May 2012 I shall announce in my blog about further exciting developments.

If you have not registered for the next workshop, then what are you waiting for, just log on to http://www.graficaindia.com today and reserve your seats.

Meanwhile, thanks DAWN HOHL of Uncommon Enterprises LLC, USA for sending many tips and technical information on water based discharge inks and many other parameters related to garment screen printing. DAWN has always been very cooperative since the inception of DMI and very few technical experts like her would share their information with others.

Thanks DAWN for your continued support…

Then, thanks to MARK COUDRAY of TShirtSuccess,LLC, USA (www.coudray.com) for helping me with solutions to my queries related to mesh selection, inks many other factors related to garments. In fact he was so much supportive that whenever I asked him any questions he gave me accurate and prompt reply which helped me to complete my R&D quickly.

Thanks Mark for your prompt replies and showing keen interest in my developments.

Finally I cannot end my blog thanking The Great CHARLIE FACINI of Freehand Graphics (www.softwareforscreenprinters.com) who was quite generous to donate free licenses of SEPARATION STUDIO and ACCURIP to DMI for our research and trial purpose. With his great innovations we could achieve fantastic results using SPOT PROCESS TECHNIQUE and we could print dramatic photorealistic images on white and dark garments

Take care and have a great week ahead.

Bhargav

For the first time in the world Exclusive Workshop on Textile (Garments) Screen Printing

I am proud to announce that DMI (Dhirubhai Mistry Institute) will be the first institute in the world to conduct 3 DAYS exclusive workshops on Textile (Direct-to-garment) Screen Printing for FREE.

The information given below will give you complete idea about the content of my next workshop scheduled 5 to 7 April 2012.

Register soon… Limited Seats…

Bhargav

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