SCreen

Printing
TeChnology
Screen Printing Frames, Screen
Press, Surfaces Printing,
Printing Process, Tabulation
Introduction

Screen printing is a printing technique whereby a mesh is used to

transfer ink onto a substrate, except in areas made impermeable to the
ink by a blocking stencil. Screen printing is also a stencil method of
print making in which a design is imposed on a screen of polyester or
other fine mesh, with blank areas coated with an impermeable
substance. Ink is forced into the mesh openings by the fill blade or
squeegee and by wetting the substrate, transferred onto the printing
surface during the squeegee stroke.

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 As the screen rebounds away from the substrate the ink remains on the
substrate. It is also known as silk-screen, screen, serigraphy, and serigraph
printing. One color is printed at a time, so several screens can be used to
produce a multi coloured image or design.

Screen printing is arguably the most versatile of all printing processes. It can
be used to print on a wide variety of substrates, including paper, paperboard,
plastics, glass, metals, fabrics, and many other materials. including paper,
plastics, glass, metals, nylon and cotton.

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 Some common products from the screen printing industry include posters,
labels, decals, signage, and all types of textiles and electronic circuit boards.
The advantage of screen printing over other print processes is that the press
can print on substrates of any shape, thickness and size.

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, foot wears, PCBs, ceramics, etc) and non-flat substrates, by using
appropriate machinery and inks.

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 The most important piece of equipment for screen printing is the screen. The
simplest screen for screen printing is nothing more than a piece of mesh
stretched across a square wooden frame. In order to make a stencil on the mesh,
an image is first drawn on the mesh. Certain areas of the mesh are then covered
with an ink- blocking substance, which makes it impossible for ink or paint to
pass through. Utilization of screen printing presses has begun to increase
because production rates have improved.

Today, Screen printing offers ample innovation and creativity, thus playing a
major role in printing industry because of the availability of advanced screen
printing machines, UV technology coupled with availability of innovative
special effects inks.

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 Screen printing is now quicker, cheaper, produces better quality images and offers
a number of special applications. 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.

Screen printing has its own distinct advantages – versatility, suppleness, wide
range of applications, brightness and solidity of colours for outdoor applications,
possibilities of special effects in graphic and textile; and wide range of presses
available for different applications. It also provides a possibility of combination
printing with other imaging and printing processes like offset, digital, etc.

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 Some fundamentals of this book are basic concept and classification of stencils, basic
screen printing process, basic registration techniques, screen printing frames, pre
treatment of screen printing fabrics, screen printing press, principal of screen process
printing, printing on paper and card, printing on vertical surfaces, printing on shaped
objects, cylindrical object printing, printing on uneven surfaces, ceramic and glass
printing, printing on plastics etc. This method of Printing has achieved wide spread
popularity since the Second World War, although the basic ideas in this process were
used by the Chinese centuries ago.

The present book contains latest technologies of screen printing along with machinery
photographs, addresses of suppliers of machinery and raw materials. This book will be
very helpful to new entrepreneurs, existing units and for those who want to diversify in
to this field.

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 Table of Contents
1. Introduction
What is Screen Printing?
Seeking a challenging and creative career? Screen
printing is ancient, yet a highly revolutionary industry
Print on virtually anything
Screen printing is universal - you see it
everywhere
Screen printing is simple
Screen Print Materials Frames
Screen Mesh Screen
Prep Tape Stencil
Systems
Capillex Film (Pre-Sensitized Photo Stencils) G&S
Pigment System

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 Essential Components
Base
Pigment
Resfix
Anti-
bleedScree
n
Softener
Ink Retarder Creating
Artwork
Other basic Tools and Supplies Creating a
Positive by Hand Rubbing Dry Transfer
Lettering onto Clear Acetate (Transtay)
For Straight Type For
Arched Type
Tracing an Image onto
Matte Acetate
Assembling Base Art
Putting together all parts of your artwork - images and message Cutting the Image
out of Masking Film
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 For All Multi-Colour Artwork
Labeling Artwork
Mesh Preparation
Roughening the Mesh
Procedure Degreasing the
Mesh Procedure
Preparing the Stencil Using
Capillary Film Using Direct
Emulsions Mixing the
Emulsion
Coating the Emulsion onto A Screen Storage and
Handling of Stencil Materials Capillary Films
Direct Emulsions
Exposing the Stencil
Positioning the Artwork: Size and Placement of Image on Substrate Positioning the
Artwork on the Screen

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 Exposing Units
Table Top Exposing Unit
Features
Building An Exposing Unit The
Fluorescent Tube Unit To Expose
The Plate Light To
Expose
Exposure Time of Different Stencil Materials Direct
Emulsions
Preparing the Screen For Printing
Washing Out the Stencil
Blocking Out Pinholes Taping
the Screen Printers
Table Top 4 Colour Printer Printing
on A Table Surface Off-Contact
Printing

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 Printing Flood
Stroke Print
Stroke
Stencil
Removal/Scree
n Reclaiming
Reclaiming A Screen Removing
Tape And Ink Removing Stencil
Material Procedure
Removing Stains Or Ghost Images
with
Autohaze
Procedure
Roughening the Mesh with Autoprep
Degreasing the Mesh with Universal Mesh
Prep
Review - Screen Reclaiming Fault
Finding Guide Capillex Films

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 Stencil film washes off mesh
Ragged edges
Fine detail filling
Pinholes
Poor adhesion Patchy
stencil Difficult
washout Direct
Emulsions
Sawtoothing
Exposed emulsion washes off mesh Fine
detail filling in
Premature stencil breakdown
Pinholes
Scumming
Image does not wash out at all

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 2. Screen Printing
Historical Background
Introduction
Section 1
Basic Concept and Classification of Stencils The
Stencil
Types of Stencils
Fabric and Frame Preparation Screen
Fabrics
Screen Frames
Fabric Stretching Techniques
Mechanical Stretching
Hand Stretchig Fabric
Treatment
Photographic Stencil Methods Direct
Process Direct/Indirect Process

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 Determining Photographic Stencil Exposures Indirect
Photographic Stencil Process Exposure

Development and Washing

Application of the Stencil Drying

Removal of the Base Material Direct

photographic Stencil Process Preparation
Application
Drying
Exposure
Development
Masking the
Stencil
Preparing a Paper Mask Preparing a Lquid
Block-out Mask Squeegee and Ink
Considerations

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 Selecting the Proper Squeegee Shape
Chemical Makeup
Flexibility Length
Squeegee Preparation
Selecting the Proper Ink
Product Characteristics
Production Limitations Ink
Preparation
Basic Screen Printing Process Basic
Registration Techniques
On-Contact and Off-contact Printing Printing
the Stencil
Multicolor Printing
Drying the Image
Cleaning the Screen

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 Removing the Stencil Troubleshooting
Clogged Screens
Halftone Reproduction in Screen Printing Methods of
Halftone preparation for Screen Printing
Fabric Selection
Moire Patterns
Printing
Considerations
High-Speed Production Presses
Semiautomatic Presses
Fully Automatic Presses Special
Machine Configurations Screening
Cylindrical surfaces Carousel Units

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 3 Screen printing frames
Pre-treatment of Frames Stretching
equipment Pneumatic stretching
clamps Advantages
Mounting
Components of the SST system
Correct stretching
Optimum tensioning force for different fabrics Stability
Control of tension in measuring fabric stretch Stretching
at a fabric angle
Stretching methods
Angled stretching with a prop profile
Adhesive
Adhering screen printing fabrics onto the frame

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 Screen Storage
The manufacture of diapositives Manual
diapositives
Photographically prepared diapositives Important
Stencils
Pre-treatment of Screen Printing Fabrics Stencil
making
Manual stencils
Photo-mechanical stencils
Manual stencil making The
hand-cut stencil
Water soluble hand-cut film
Cellulose hand-cut film Causes of
errors
Bad adherence
Turned-up film edges
The direct stencil with emulsion

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 General procedure
Sources of errors with direct stencils lmade
only with emulslion Formation of fish-eyes
after coating Air inclusions during coating
Poor adherence of the photo emulsion after exposure Light scatter
when copying (loss of detail)
Saw-tooth effect Half-
tone printing
Difficulties in decoating Stencils for
water-based inks Emulsions (photo
emulsions) Sensitizers
CHROMATE photo emulsion
DIAZO photo emulsions Printing
requirements
Lines

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 Half-tones
UV-inks
Fineness of fabrics
Examples for coating
The direct stencil with film
and emulsion
General procedure
Sources of errors with direct stencils made
with film and emulsion
Bad adherence of the film on the fabric Use of
too fine a fabric
Too hard or too sharp a squeegee
Dust inclusions
Too short an exposure time Error
in exposure
General procedure
Source of errors with direct stencil
made with film and water
Bad adherence of the film on the
fabric
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 Insufficient treatment of the fabric Error in
exposure
Indirect stencil
General procedure
Sources of errors with indirect stencils Bad
adherence of the film on the fabric Insufficient
treatment of the fabric Insufficient degreasing of
the fabric Too long an exposure time
Inactive developer
Drying the stencil with warm air Exposure
Hardening of stencils for printing of water based colours in textile printing
General procedure
The hardening procedure

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 Attention
Suggestion
The diapositive
The stencil
Steel and light-
alloy frames
The linear co-efficient of thermal expansion Frame
distortion by fabric pull
Warping of the frames under various mechanical stresses Steel versus
Aluminium
Recommendations for frame size and profile
Screen printing fabrics
Optimum tightnes of the fabric stretch Degree of
Stretch
Gluing the fabrics to the printing frames The
printing substrate
Stencils for half-tone printing Types
of screen rullings Printing

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 Setting a flat bed printing table SST-
measuring wedge
The squeegee
Squeegee System
Flood coat squeegee (Doctor blade)
Printing speed
Printing shaped objects
Single operation multiple colour printing

4. The difference between multi-filament & mono-

filament screen printing
fabrics
UV-Goldorange

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 5. Screen Printing Press
The Screen-Printing Press
Types of Fabrics Construction
of Fabrics
Mesh Count, Mesh Strength, and Mesh Opening
Stretching The Screen Fabric
How to Build A Screen-Process Press? Step
1 :Assemble Needed Materials Bill of Materials
Step 2 : Construct the Frame Step 3:
Attach the Screen Fabric Step 4: Tape
and Seal the Screen Step 5: Prepare the
Base
Step 6: Hinge the Frame to the Base
Step 7: Add a Frame Support

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 Print drying equipment Constructing
Specialty Equipment
Screen Printing On: Papers, Textiles and Other Printing Substrates
Type of Paper
Principal of Screen Process Printing
Common Types of Paper
Color of Stock
Textiles
Type of Fabric
Common Types of Fabrics
Printing on T-shirts Plastics
Types of Plastics
Metals
Woods
Ceramics
Screen-Process
Stencils

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 Hand-cut Paper Stencil
To Prepare a Paper Stencil Step1:
Image the Paper Step 2: Cut the
Stencil
Step 3: Adhere the Stencil
Hand-cut film stencil
To prepare a Film Stencil Step 1:
Prepare for Cutting Step : Cut
the Stencil
Step : Adhere the Stencil
Step 4: Remove the Backing Sheet
Photographic stencils
To Prepare an Indirect Photographic Stencil Step 1:
Prepare for Exposure
Step 2: Load the Frame Step 3:
Expose the Stencil Step 4:
Develop the stencil

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 Step 5: Wash Out the Stencil Step
6: Adhere the Stencil
To Prepare a Direct Photographic Stencil Step 1:
Mix the Emulsion
Step 2: Coat the Screen Step 3:
Expose the Screen Step 4:
Process the Stencil
To prepare a Direct/Indirect
Photographic Stencil
Step 1: Sensitize the Coating Solution Step 2:
Adhere the Film to the Fabric Step 3: Expose
the Stencil
Step 4: Wash out the Stencil
Screen Printing
Automatic Press
The printing form makes it possible
The screen printing features and
their singularity

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 Choosing A printing Process
Letter Press
Advantage
Limitations
Lithography
Advantage
Limitation Photo
Gravure Advantage
Limitation Screen
Printing Advantage
Limitation Collo
Type Advantage
Limitation Flexo
Graphic
Advantages
Limitation
What process to use

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 6. Printing On Various Surfaces Printing
on Paper and Card Articles With Thick
Surfaces Printing on Metal & Metal Foils
Textile Printing

Textile Inks
Make Ready
Very long Banners
Printing On Vertical Surfaces
Printing On Shaped Objects
Cylindrical Object Printing Printing
on Uneven Surfaces Ceramic and
Glass Printing Printing On Plastics
Summary

7. The Printing Process

Actual Printing Elementary
Work

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 Selection of Ink
Use of Squeegee
Coating of ink layer
Racking or Drying
Multi - Colour Screen
Printing
Colour Scheme Colour
Separation Temporary
Blockout Permanent
Blockout
Single Operation Multiple Colour Printing Printing
of coloured background (Patch) Halftone Printing
Preparation of stencil for half tone printing Stickers
(Transfers)
Transfer stickers
Gumming
Cleaning Operations
Summary

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 8. Tabulation
Polyester Monofilament
Nylon Monofilament
Metallized Polyester Monofilament UV-
Goldorange
Polyester Monofilament
Fabric number
Carbon

Machinery Section

Director Section

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 Niir Project Consultancy Services (NPCS)
can provide Process Technology Book on
Screen Printing

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 Contact us
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 AN ISO 9001:2008 COMPANY

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Who are we?

o One of the leading reliable names in industrial world for

providing the most comprehensive technical consulting
services

o We adopt a systematic approach to provide the strong

fundamental support needed for the effective delivery of
services to our Clients’ in India & abroad

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We at NPCS want to grow with you by providing solutions scale
to suit your new operations and help you reduce risk and give a
high return on application investments. We have successfully
achieved top-notch quality standards with a high level of
customer appreciation resulting in long lasting relation and large
amount of referral work through technological breakthrough and
innovative concepts. A large number of our Indian, Overseas and
NRI Clients have appreciated our expertise for excellence which
speaks volumes about our commitment and dedication to every
client's success.

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We bring deep, functional expertise, but are known for
our holistic perspective: we capture value across
boundaries and between the silos of any organization.
We have proven a multiplier effect from optimizing the
sum of the parts, not just the individual pieces. We
actively encourage a culture of innovation, which
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ensures a high quality product.

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What do we offer?

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How are we different ?

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consultancy and market research field
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and profound market analysis
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Our Approach

Requirement collection

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Project

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survey/research

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Who do we serve?
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Sectors We Cover

o Ayurvedic And Herbal Medicines, Herbal Cosmetics

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Resin
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Sections,
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Assembling

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Sectors We Cover Cont…

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Projects
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Food
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Repellents,
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o Fruits & Vegetables Processing

o Ferro Alloys Based Projects
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(Biofuel)
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Sectors We Cover Cont…

o Infrastructure Projects
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Bags
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Sectors We Cover Cont…

o Paints, Pigments, Varnish & Lacquer

o Paper And Paper Board, Paper Recycling Projects
o Printing Inks
o Packaging Based Projects
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Based Projects
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o Plastic, PVC, PET, HDPE, LDPE Etc.

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Sectors We Cover Cont…

o Potato And Potato Based Projects

o Printing And Packaging
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Hospitality
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o Township & Residential Complex

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o Wood & Wood Products
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Mineral Water)
o Wire & Cable

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 Contact us
Niir Project Consultancy Services
106-E, Kamla Nagar, Opp. Spark Mall,
New Delhi-110007, India.
Email: [email protected] ,
[email protected]
Tel: +91-11-23843955, 23845654,
23845886, 8800733955
Mobile: +91-9811043595
Fax: +91-11-23841561
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