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How to design a screen making room.
- 1. How To Design A Screen Making Department – Textile Screen Printers William Shorter CPS Technical Sales Executive/Product Manager
- 2. How To Design A Screen Making Department • The screen is the very heart of the screen printing process • Without a quality screen it is impossible to get a quality print • Where and how that screen is made will have a huge impact on the result • In many companies screen making is dirty, difficult and costly; however with a good design screen making can be clean, quick and profitable!
- 3. The Good And The Bad!
- 4. A Recipe For Disaster! Exhaust fan not working Shelves not fixed to the wall Open container Unlabelled containers No gloves No goggles Not waterproofed electrics Trip hazards No safety shoes Slip hazard Untidy
- 7. Good Design Is All About Process Flow • What is the process flow? • How many screens do I need per day? • How to avoid unnecessary handling? • How to separate clean from dirty • How to separate dry from wet • What are the critical areas for contamination?
- 8. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval
- 9. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval Screen making is separated into two areas: screen cleaning and screen making Screen cleaning is dirty and screen making is clean
- 10. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval Use white light in the screen cleaning area as it is much easier to examine a screen under white light than yellow Always use yellow safe lights in the screen making area
- 11. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval Dirty screens are brought in from the production area If you have a standard screen size, use mobile racking which can be wheeled in and out Screens are very expensive – do not leave them leant up against a wall as they will become damaged
- 12. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval Many screen cleaning chemicals are hazardous. Use a proper storage cabinet to keep them in especially if flammable solvents are used. Check with your insurance company how much flammable material you can store inside per room, typically 50 LT max. The operators should use gloves, goggles, aprons and boots when handling screen cleaning chemicals
- 13. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval The first step is to remove the old ink off the screen Use a dedicated screen cleaning booth for this Make sure there is good ventilation to exhaust the solvent vapours away from the operator. Make sure you use low evaporating solvents. Use recirculation of the solvents to minimise cost
- 14. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval Use a separate screen cleaning booth for stencil removal Make sure there is both a low pressure water spray as well as a high pressure gun – Never rinse off chemicals with a pressure gun The booth should be equipped with an exhaust fan especially if haze removers are used Use a white back light to inspect the screens This area will become wet – use non slip mats in front of the booth
- 15. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval The final stage in cleaning is degreasing TOP TIP: Use an in-line water filter to remove dirt from the water supply
- 16. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval To reduce contamination fit double sided vertical drying cabinets between the two areas This way screens can be loaded into the dryer from the cleaning area and unloaded from the screen making area
- 17. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval The screen making area should be a controlled cleanliness area to reduce contamination Top Tip for the best screens: Operators should wear ‘clean room’ clothing as most contamination comes from people If you can maintain a positive pressure in the room this will limit the amount of dust that comes in
- 18. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval Try to reduce the number of times that the door has to be opened and make sure it is a ‘self closing’ door Position tack mats on either side of the door to pick up dust from the operators shoes. TOP TIP: place tack mats in front of the coating machine / coating stand as this is a critical contamination point
- 19. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval
- 20. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval Minimise the distance between the coating machine and the horizontal screen dryer. Dust is impossible to remove once it has landed on a wet coated screen Coated screens can be stored vertically once they are dry
- 21. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval A HEPA filter fitted to the air conditioning unit will provide a dust free environment The ideal conditions are 55% Relative Humidity and 20°c TOP TIP: use the CPS safelight indicator to test your safelights
- 22. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval Reduce UV reflections by painting the exposure area matt black Make sure there is no light spillage from the exposure unit which could fog coated screens, or injure the operator
- 23. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval Fit an in-line water filter to the washout spray Use both a strong shower spray and a pressure gun for the washout The washout booth must be fitted with a back light for ease of inspection Fit a non-slip mat in front of the washout as this area will become wet
- 24. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval After washout, the screens can be dried vertically Use warm air to ensure screens are fully dry before printing
- 25. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval Once dry the screens can be spotted out before printing A near vertical inspection light box is easier to use for large screens
- 26. Verticalrackfor dirtyscreens Pressure washer Stencil& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval
- 27. Verticalrackfor dirtyscreens Pressure washer Degreasing& Hazeremoval Non-slipmat Screencleaning chemicalsstorage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea DipTankAll-In- One
- 28. Verticalrackfor dirtyscreens Pressure washer Non-slipmat Screen cleaning chemicals storage Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction PPE Storage In-line water filter Clean room clothing Coated screen storage Screencleaningarea WashoutboothWashoutboothDiptankDiptank PPEStorage
- 29. Vertical loading station Pressure washer Stencilremoval Non-slipmat Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction In-line water filter Clean room clothing Coated screen storage Screencleaningarea Inkremoval Screen cleaning chemicals storage Vertical unloading and drying station Washout booth PPE Storage
- 30. Vertical loading station Pressure washer All-in-oneinkandstencilremoval Non-slipmat Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction In-line water filter Clean room clothing Coated screen storage Screencleaningarea Screen cleaning chemicals storage Vertical unloading and drying station Washout booth PPE Storage
- 31. Vertical loading station Pressure washer All-in-oneinkandstencilremoval Non-slipmat Washout booth Non-slip mat Tackmat Vertical dryer for degreased screens Vertical dryer for processed screens Emulsion storage & worktop Coating machine Tack mat Exposure unit Horizontal dryer and light box Pressure washer HEPA filter air conditioning to create a positive pressure Worktop and storage Screen making area Yellow safelight Self closing swing door Vertical light box for retouching Work flow direction In-line water filter Clean room clothing Coated screen storage Screencleaningarea Screen cleaning chemicals storage Vertical unloading and drying station Washout booth PPE Storage
- 32. Summary • Screen making is the most important part of the screen printing process • Designing a practical, efficient screen making department does not cost much and can mean the difference between profit and loss
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