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For Textile application, two kinds of Textile Emulsion can be used; 6061-015 Diazo Textile Emulsion 015 and 6061-401 One Pot Textile Emulsion 401. Both emulsions are specifically designed for printing water-based and plastisol inks. Diazo Textile Emulsion is a two pack system emulsion while One Pot Textile Emulsion is a pre-sensitized emulsion.
There are 3 types of Emulsion for graphic applications namely: Diazo Graphic Emulsion, Dual Cure Graphic Emulsion, and High Build Graphic Emulsion. Each type of emulsions is designed for a specific application. Please see the description on the website or open TDS for detailed information.
Recommended mesh for T-Shirt and Sportswear Printing using water based inks is P48-70 Y.
The range of mesh counts you may use may determine a certain viscosity in the emulsion. Coarse mesh counts require higher viscosity, high mesh counts ask for lower viscosity. Some emulsions are not suitable to be coated on fine meshes of coarse mesh counts, whereas others may be suitable to handle everything from 63 tpi to 470 tpi. Recommended mesh for fine detailed images is P120-34 Y.
Diazo is a two-pack emulsion (Base + Sensitizer) while SBQ is a one pot ready to use emulsion. Diazo-sensitized emulsions can offer very good overall quality with acceptable exposure times. In moderate climates these emulsions are suitable for fine detail printing. They are available as either solvent or water resistant emulsions but unfortunately cannot offer perfect solvent resistance with good water resistance in one. Diazo stencils offer acceptable copying qualities. SBQ-Photopolymer emulsions are one component pre-sensitized systems with extremely fast exposure times. Due to the exposure speed, the exposure latitude is very short and the risk of either over or under exposure is fairly high. Mesh bridging, resolution and edge definition can vary but is in most cases fully comparable with high quality diazo emulsions. This system offers very good resistance to humidity and is available in water and solvent resistant versions. The resistances, however, cannot match the resistances of Diazo-photopolymer sy
Sensitized emulsion usually lasts for 1 week at 20ºC.
SBQ Emulsions including all other emulsions have shelf lives of 1 year.
The correct exposure time depends on number of factors including the type of light source, the mesh count, the emulsion thickness, the detail required and the colour of the screen mesh as well as the transparency of the positive film and the glass clarity of the vacuum frame. SBQ emulsions have usually longer exposure time than diazo emulsions.
Water resistant emulsion is used when printing textile water-based inks and textile plastisol-based inks. 6062-201 Dual Cure Ceramic Emulsion can also be used for printing water-based, plastisol-based and solvent-based inks.
Solvent resistant emulsion is used for printing mostly on graphic using solvent-based and conventional UV inks.
UV resistant emulsion is used when printing with UV inks.
For normal printing, 1-2 coats, wet-on-wet to the printed side of the screen followed by one or two coats wet-on-wet to the squeegee side. If higher build is desired, extra coats should be applied to the squeegee side of the screen.
Exposure time varies on a number of factors which includes the type of light source, the mesh count, the emulsion thickness, the detail required and the colour of the screen mesh as well as transparency of the positive film and the glass clarity of the vacuum frame. SBQ emulsions have longer exposure time. And diazo emulsions have lesser exposure time. Please see TDS of each emulsion for detailed information.
The stain remover is a mixture of strong solvents which softens hardened ink and washes the residues out. The ghost remover is an alkaline based paste which breaks the chemical compounds (a combination of emulsion and ink due to underexposed stencils) into soluble fractions.
The screen hardener reacts with the emulsion making the chemical compound insoluble. (Difficult to remove the stencil after printing)
Hardener should be used when printing long runs with water based inks.
Mesh Prep is used for better adherents of indirect stencils to the mesh. Mesh prep roughens the surface of the mesh and this minimises the repellents of water, gives an even water flow and an even adherence of the film. Mesh Prep can also be used before applying emulsion.
Every mesh should be thoroughly cleaned and degreased before applying the emulsion. The answer to this question is: “ALWAYS”.
Mesh has to be degreased every time before applying emulsion or film. Also a new mesh has to be degreased.
The 2 component adhesive hardens within 20 to 30 minutes. Humid air accelerates the hardening time.
About 30 minutes. Therefore one should mix just the amount needed for one or two frames.
All products are good, however the most commonly used is the powder for its economical use.
On PVC material it is recommended to use solvent based PVC-ink as well as UV-ink. As there are so many different types of PVC materials (vinyl sheets, hard PVC-sheets, boxes and bottles etc.) it is recommended to ask the ink supplier about the best usable ink for the actual substrate.
The substrate is the base on which an image will be printed on.
4 colour process printing is a very sophisticated system to print a vast range of colours with only 4 basic colours: Yellow, Magenta, Cyan and to deepen the shadows, Black. Usually it is used to reproduce photographic pictures but it can also be used for any other coloured print.
As the word already indicates we need 4 frames: Usually the first printed colour cyan, then yellow, magenta and last black. It is important that all 4 frames have the same mesh and the same tension.
For outdoor applications such as advertising, recommended is Gloss PVC Ink 3000.
Varnish protects the printed image from the influence of weather, sun and especially from UV-light. The colours look brighter and the whole print has a better appearance.
All UV-Inks have to be exposed to strong UV-light for drying.
No, UV-Ink needs a UV-drying unit. Exposing UV-ink to the sun does not work for commercial use.
The possible causes and solution to each problem 1. Poor contact during exposure (Solution: Check vacuum) 2. Underexposure (Solution: Perform Step Wedge Test) 3. Light scattering (Solution: Use dyed mesh) 4. Insufficient washout (Solution: Wash from both sides) 5. Poor buildup of emulsion (Solution: Improve coating technique) 5. Mesh too coarse (Solution: Use higher mesh count)
The possible causes and solution to each problem 1. Improper mixing of sensitizer (Solution: Dissolve sensitizer thoroughly, mix well with emulsion) 2. Under exposure (Solution: Perform Step Wedge Test) 3. Emulsion too old (Solution: Review storage guidelines) 4. Positive’s yellowed (Solution: Use new positives) 5. Excessive humidity (Solution: De-humidify area, increase exposure)
The possible causes and solution to each problem: 1. Coating not uniform (Solution: Upgrade mesh stretching and coating procedure) 2. Improper mixing of sensitizer (Solution: Dissolve sensitizer thoroughly, mix well with emulsion) 3. Underexposure (Solution: Perform Step Wedge Test) 4. Improper mesh preparation (Solution: Degrease all mesh; roughen and degrease synthetics) 5. Washout temperature too high (Solution: Washout below 100° F) 6. Emulsion too old (Solution: Review storage guidelines) 7. Emulsion not dry before exposure (Solution: Dry screen sufficiently; use screen drying cabinet) 7. Excessive humidity (Solution: Increase exposure; dehumidify shop)