Printing For Team Business – Screen Print versus Heat Press

Printing for Team Business – Analysis

Introduction – The technical fabrics that make up today’s team marketplace are complex in their performance and no surprise are complex to print. When printing or entering the business of decoration for the team market, various technologies must be considered and it is my opinion that ultimately a combination of technology will provide the most complete solution to embellishing all types of fabrics for team wear.

To start we need to consider the fabric types that a business catering to ‘team business’ will want to decorate.

Here is a list of common applications as well as constructions:

· Team Warm Ups: Tricot Polyester, Cotton/Polyester Fleece, Polyester Spandex, Micro-Polyester, Nylon

· Jackets: Tricot Polyester, Micro Polyester Windbreaker, Nylon, Microfiber Polyester,

· Polos: Polyester Performance, Cotton/Polyester, Cotton

· T-shirts, Sweatshirts: Cotton, Cotton/Polyester, Polyester Performance

· Uniforms: Cotton/Polyester, Polyester, Polyester Mesh, Nylon, Nylon Mesh, Spandex, Nylon Spandex, Nylon Dazzle, Polyester Dazzle

· Performance Apparel: Polyester Loose Fit, Nylon/Spandex Compression, Polyester/Spandex Compression

· Bags: Denier Polyester, Canvas, Polypropylene, Nylon

· Headwear: Polyester, Cotton, Cotton/Lycra, Plastic

Here is a list of the viable decorating methods to apply logos, lettering and numbering to the said items;

· Screen printing (w/a number machine for certain applications)

· Heat Transfer via Cad-Print Technology

· Heat Transfer via Cad-Cut / Die Cut Technology

While I believe Heat Transfer via Cad-Print Technology is the future in this market, screen printing and heat transfer via Cad-Cut / Die Cut technology are the more traditional methods.

So let’s first take a look at Screen Printing for team uniforms….

Team uniforms pose a variety of challenges for screen printing. The most effective way to number team uniforms is with a numbering machine. There are many varieties of numbering machines in the marketplace – all of which operate under similar principles. A number screen must be burned and housed for every unique font in every size. Consider if your company wanted to offer 10 font choices. You would need to have a screen (roughly 20” x 6’) for 4”, 6”, 8”, 10” & 12” numbers in each font – this equals 50 screens just for one color work. If you wanted to offer two color numbering in each size expect to double this number of screens giving you 100 screens to invest in and store. As a last consideration, think about the different recommended mesh counts for varying fabrics, and you’ll find yourself having a significant inventory of screens. One last inventory concern is the stocking of ink colors. Inks come in a variety of colors for a variety of applications. Ink cost is very minimal when on the garment, but you must consider the inventory dollars tied up in various formulas for specific uses across your offered color range – the money in ink can begin to add up.

Once you receive a job you will need to print it. Printing athletic types of fabrics involves special inks designed for each application. The general process for a two color, two digit number involves:

Loading your numbering screen of choice and printing your foreground color for each digit (two steps). After all of your foreground numbers are printed you will want to flash them. Now change out your screens and print the background color over top of the foreground. In screen printing, two color numbers are typically produced using a technique called trapping to allow for proper registration. This means that your second application will slightly overlap your base color. You will need to use a non-migrating ink as your base color if the foreground color is a lighter shade. After the second color is printed you will need to flash cure again. Another consideration when printing uniforms that can pose a challenge is printing mesh jerseys. When printing mesh, you must be careful that ink that when the ink pushes through the mesh holes that it does not stay on the platen and potentially damage the jersey as its unloaded or as the next one is loaded. To avoid this, screen printers often add in an extra step of replacing a protective cardboard square on the platen after each jersey. This can add to production times and incrementally to costs. One last consideration for the team uniform market is the issue of dye migration. Ink manufacturers today have low bleed inks specifically for polyester based jerseys that pose migration issues. Low bleed inks will help to limit migration but do cost more which must be considered when lettering uniforms. Also, currently with this process there is not an ink on the market that has a no bleed claim, leaving the possibility of slight migrating after the garment is laundered.

Now let’s look at Cad-Print for uniforms….

Cad-Print in general is a fairly simple process for team uniform logos, lettering and numbering and is the most viable digital decorating process for this market. The highest volume shops that do uniform fulfillment use the 54” printer. The printer is loaded with a roll of printable white film that is backed with a clear plastic or paper. The artwork is designed in a graphics program and digitally output to the printer. The printer uses a combination of CMYK ink and depending on the model of printer sometimes light cyan and light magenta to print your art. Operators typically gang up print runs by team or batch and send all of the name/number combinations at once. After the unit is done printing the roll it retracts the material back into the printer to begin a cutting process. A blade cut around each name, number or logo preparing the material to have the excess white film removed. Below are photos of the various steps in the process:

Weed away the excess material after your design has been printed and cut.

Apply a masking material to lift your design – for higher volume shops this process can be automated through the use of a cold laminator.

Pick up your design by lifting the mask – then take your pre-spaced art over to your heat press to apply to your garment of choice.

Heat apply your design and remove the masking material.

From my point of view there are many advantages to this workflow.

1. You print the colors you want.

a. This eliminates the need for an inventory of ink

b. This gives you the opportunity of unlimited color offering without having to order another color.

c. You can color match.

d. Fills, gradients, repeated team logos, special effects and 3 or 4 colors numbers are all doable.

e. Full color team logos are easy

2. You print the sizing you want.

a. No need for a screen for every size number

3. Names are easy to do.

a. Just add the name to your number and print a combo that is pre-spaced and easy to apply.

4. You save money on inventory and space.

a. Different types of rolls with special adhesives are available for various fabrics, but you need only stock a few varieties

5. We have an answer for dye migration.

a. We have a no bleed material for polyester.

6. We have an answer for stretchable fabrics

a. We have a material that stretches and rebounds that is used by industry leaders.

7. More breathable on White Mesh

a. We have a special material that will clear the holes on white mesh of many fabric constructions

Those are the basic arguments for team uniforms – now onto the other team related apparel.

On other types of apparel, the answer is not as definitive. A lot of the decision comes down to the number of pieces that you will need to decorate with a logo. The rule of thumb is that if each piece is unique (meaning a different name or number) than the Cad-Print process will be the way to go. However, the ‘other’ size runs will need to utilize both technologies at various thresholds.

Let’s look at a few examples:

Example #1

This particular team logo consists of 5 colors and for this job I will need it in a 6 x 6” print size.

To complete this job whether 1 piece or 1000 pieces out of Cad-Print the cost is going to remain relatively close. This cost will vary slightly based upon the white printable film type that I need to use, but I can estimate the final cost to come in at 72 cents on the low end material and $1.44 on the absolute high end. So for demonstration purposes I will average the cost to $1.08 per piece. Labor will need added to this.

To screen print this same job I would need to evaluate based in # of colors and quantity produced – not necessarily size. Since we already know it is a 5 color piece of art, I know that I will need to burn 5 screens at about $20 per screen. This incorporates $100 into the cost to start. Depending on the type of ink needed based upon the fabric that I am applying it to; the ink cost will range from pennies to about a dime per design. I will use 5 cents as an average.

So let’s take a look at my cost in materials to produce this at various quantities:

1 Piece: Screen Print $100.05 Cad Print $1.08

10 Pieces: Screen Print $10.00 Cad Print $1.08

20 Pieces: Screen Print $5.00 Cad Print $1.08

50 Pieces: Screen Print $2.00 Cad Print $1.08

75 Pieces: Screen Print $1.33 Cad Print $1.08

100 Pieces: Screen Print $1.00 Cad Print $1.08

Now let’s take a look at how this same principle applies to a two color logo:

Example #2

This logo is 2 colors and we will want it in the same 6 x 6” size.

Screen Printing = $20 per screen x 2 colors = $40 + $0.05 in ink = $40.05

Cad Print = $1.08 average, based on the above example

1 Piece: Screen Print $40.05 Cad Print $1.08

10 Pieces: Screen Print $4.05 Cad Print $1.08

20 Pieces: Screen Print $2.03 Cad Print $1.08

40 Pieces: Screen Printing $1.01 Cad Print $1.08

50 Pieces: Screen Print $0.80 Cad Print $1.08

Based on the two examples above you can see how design size, number of colors in the design and number of pieces will affect whether or not to use screen printing or cad printing. This is one reason why I believe both are important.

Having set this as a general rule of thumb there are always instances where you will want to use one process over the other for specific performance reasons. Here are some instances.

· Many shops prefer Cad Print over Screen Printing for stretchable fabrics. This is primarily because of their ability not to crack when stretched and the ease of applying the logos onto this type of fabric via a heat press.

· Cad Print over Screen Printing on some garments that have definite dye migration issues.

· Screen Print over Cad Print for the absolute softest feel on a cotton fabric.

· Cad Print for bags and other odd shaped items that are tough to accommodate on a screen printing press

· Cad Print over Screen Print for nylon jackets due to eliminate the need for a catalyst when screen printing

· Cad Print over Four Color Process Screen Print when photos, color vibrancy and retention is needed

These are just a few examples that are based on my experience in customer’s shops of all sizes.

One other consideration when considering whether to implement Cad Printing technology is whether or not you will be able to utilize the printer used in the system for other applications.

Common applications that team oriented shops excel in include:

· Helmet Decals

· Banner Printing

· Poster Printing

· Repositionable Wall Graphics

· Locker Magnets

· Canvas Photo Prints

· Window Clings

· Bumper Stickers

To summarize, I think both Screen Printing and Cad Printing are necessary technologies for a business that wants to really excel in complete fulfillment into the team sports market. Since the Cad Print systems and materials is the technology that I specialize in, I will outline a scalable package recommendation for a high volume shop.

Cad Print System

Printer/Cutter: Roland XC540 54” Printer/Cutter w/optional blower dryer to increase production times OR (2) Roland Versacamm VP300 30” Printer/Cutters

Cutter: GX-500 to handle overflow of cutting in peak seasons OR GX400

Heat Presses: Multiple Hotronix Air Swinger Heat Presses (1 unit will accommodate 60 pieces per hour – # of units recommended will be based on daily volume, shifts and production staff)

Laser Alignment System for accurate placement of transfers (1 per heat press)

Inks: Eco-Solvent Max Inks 440mL (1 set per printer)

Material Inventory not included

Estimated Cost Range: $40,000 – 60,000 (can be as low as $20,000 for budgeted start up)

Tags: customize jerseys, customize team jerseys, football lettering, football numbers, heat press lettering, heat press uniforms, heat pressing, personalize uniforms, personalized jerseys, roland, Roland Versacamm, screen print numbers, screen printed transfers, team sports numbering, Versacamm