Ink Buildup Blocking Image Area?

[mimosatexas]

So we are printing a design with six rectangles butt registered and stacked parallel to the squeegee blade on a white shirt.  After 200 or so prints we are seeing build up on the backs of the screens from the previous color in the print order to the point where it is blocking the image area where they butt up against each other and white is showing through irregularly.  I am basically carding off the buildup, giving it a quick wipe, then moving on, but this is a 3000 shirt order and we will be reprinting it again soon so I want to figure out how to avoid the build up next time around.  The stoppages are killing us...

The only thing I can think of is printing every other rectangle, adding a flash, then printing the last 3, so wet on wet for 3, flash, then wet on wet for 3, but that will change how the colors look a bit based where they fall in relation to the flash in my testing.  More thick/opaque the closer they are to the flash.

I feel like ink choice in likely an issue, though I have based down the inks quite a bit in an attempt to limit the buildup and it does help a bit, but not enough to fix it outright.  Just generally looking for thoughts on how to approach this issue moving forward.  Thanks!

[ericheartsu]

Other WOW pros will be able to explain better, but using an ink formulated for WOW, that's not thinned or based down, is going to help with that alot!

[mimosatexas]

probably the easiest solution.  What wow inks are people running on whites for runs of 3k, 5k, 10k, etc.  We are getting a couple jobs this size a month right now...

[Frog]

Besides using inks known for good WOW characteristics, of course you also want good tension.
Now, from the 35 year old arsenal of band aid fixes there's always a spritz with silicone spray, or even Pam, which will usually allow a lot longer between wipes.

[zanegun08]

Can you post the design, or something similar to show what you are talking about.

Is it possible to use smaller squeegees so where they are printing on top of each other the squeegee isn't touching the others?

Then if there isn't as much pickup or stepping on a color driving it into the garment you wouldn't affect the color as much flashing.

Posting the image would help

[Doug S]

probably the easiest solution.  What wow inks are people running on whites for runs of 3k, 5k, 10k, etc.  We are getting a couple jobs this size a month right now...

White shirts for us would definitely be wilflex epic series. 

[RICK STEFANICK]

Base your inks down with some chino, shape  or finess and your problem will be solved.

[Frog]

Base your inks down with some chino, shape  or finess and your problem will be solved.

He has said that he is basing his inks down, but did not specify which base. Myself, I use IC Soft Hand, bur also don't have the same size of runs he has.

[RICK STEFANICK]

In the old days we would use some mineral spirits..lol  It worked

[presspressmerch]

What screens are you using? Maybe the mesh is too low?


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[ZooCity]

I have seen this with otherwise hi-qual plastisols over the years.

We would print this job all with traditional WB using that 3 and 3 with a flash method you described so that abutting colors aren't printing WOW.  Actually, we would use 2 flashes and and do it 2 F 2 F 2. 

For plastisol we run Wiflex Epic Amazing Base, no additives save for the 1 in 1000 situations where we need to print an ink so transparent that the base:PC ratio is thrown and we need to put some finesse in there.   So additives only in extreme cases to rebalance the mix.   It's tempting to put the soft hand whatever base in for runs like this but fight the urge and go back and figure what's wrong with the base/mix itself first.

If printing with plastisol I really think that last part is key and will second what Eric said- use a WOW friendly ink and do not add anything to it. 

[Lizard]

You have two options. The buildup is s a combination of ink and fibers from the shirt. Option one is use a clear base, flash then wet on wet for the colors. For a job of that size that would be my preferred option it would save on ink costs and no stopping for lint. Also a he print would be vibrant for years. Second option is to print the boxes/objects towards the lower part of the shirt first then the shapes at the top portion of the Shirt last so buildup can’t block the image area. This is also a great trick when printing colors on a base to prevent blurring.