Help with new plant

[Maxie]

We are moving in January to new premises, a new building, 6500 sq ft.
Half of this is going to be for printing and half for shirts etc.      We carry a lot of stock.
It's a new  building, 18ft high ceiling and I have to layout the printing department from scratch.
We are moving because we are getting new equipment and our current place is too small.
We will have 2 MHM's, a E Type and new S Type Xtreme 14/12 and a new gas oven.     Adelco, 12 ft Oven with 4.5 ft inlet and outlet, 72" belt.
I am planning on building 3 rooms for screen treatment, first one for ink and emulsion removal.    We are already using dip tanks, copied Kitsons set up.
Second for drying screens both coated, exposed and washed, I will put the screens vertically on a stand with fans above them after emulsion removal and once they are partially dry I'll put them in the drying room.    The drying room will have air conditioning and humidity control.
I might coat in this room but I think I can coat in the factory area and put the coated screens in the room to dry.
If I remember correctly freshly coated screens are not sensitive until they dry.
The third room is for washout after exposure.      These rooms will have sound proof walls.
I want to have all screens on wagons, thought of different colors for dirty, clean and coated.
I need to work out a way to treat the water before it goes down the drain.
I'd appreciate feedback, I know some of you have set up new plants recently.
What good ideas did you have, what mistakes did you make?
Thanks in advance for your help

[mimosatexas]

Someone recently posted a pretty awesome floorplan of a 3 room screen setup like you describe.  Not sure which thread unfortunately.

[Prosperi-Tees]

There was an article in the last Impressions(i think) magazine about the ideal shop. Hopefully someone has a link to that.

[bimmridder]

http://link.asicentral.com/c.html?ufl=3&rtr=on&s=dke,1x1m8,2w47,a89n,bais,4uoa,h9tm

[Prosperi-Tees]

There you go, I stand corrected, wearables magazine.

[BorisB]

There was an article in the last Impressions(i think) magazine about the ideal shop. Hopefully someone has a link to that.

In my eyes this dream shop is not so ideal.  It's also drawn in funny scale. If total area is 14000 square feet, it's 32m by 43m.  This makes diameter of 10c auto 3,4m and length of it's dryer  9,7m.  Unusual.

I wouldn't want to have DTG close to embroidery (lint) and out in the middle of open area, close to loading dock- difficult to control humidity.

Screenmaker needs to walk a lot in this setup as drying cabinet is in longest possible distance from rinsing and developing booth.

[zanegun08]

We are remodeling our screen room currently, so I posted current, and work in progress, although that isn't exactly how it will be since we didn't want to move plumbing.

We found that we were turning screens too fast, with them not being all the way dried before imaging, causing longer exposure times, but more importantly faster break down on press.  To compensate we added a hardener, which wasn't necessary, and made our reclaim process much more difficult.

So, we have 3 climate controlled rooms, moving our coating to the middle room, with a better climate controlled drying room for emulsion.  We are keeping our current drying room for screens to go into after degreasing since unfortunately our auto-reclaimer doesn't get them degreased currently, so we have to do a post spray out.  We are still working on this, because I think we can get it so the screens are ready to go, just finding a balance.

We are also going to be adding an LED exposure unit, most likely after ISS Longbeach once we see the new units from M&R, Exile, and others which will go beside the Spyder II Computer to screen.

All LED UV protected lighting throughout, (yellow sleeves)

If I could get the screen stretching table moved out, and if we could figure out permanent block out, to avoid taping screens, I think we do have one of the best layouts for screen rooms that I have seen.  This was laid out well before I ever even was in the industry so I cannot take credit, but separating each step, and keeping the variables in control each step of the way makes for better screens.  We don't have pinhole issues, have great screens, good, consistent EOM.

Still need to work on excessive labor (old timers), we don't use S-Mesh (what's all the hype about?) and my goal is to not tape screens within the next month, so if anyone has any secrets to share I'd love to hear.

[Maxie]

Thanks for the reply's.
Zanegun, if you use CTS then why do you need a exposure table?
Saati US sell a great LED lamp that is reasonably priced,  I use one with there SBQ emulsion and expose for 40sec, some of the tables expose for 7sec.    I think that's too short a time.      If you're  one second out that's over 10%.
Check on YouTube for a video by Greg Kitson.     He just hangs the screens on the wall and exposes.
I see that you are stretching your screens, we do as well.    Just add about an 1" of glue all around when you glue the screen and leave the width of your coating trough.     This way you will need no block out.     You said you want to stop taping, from my experience it's much easier to tape the inside of the screen than to clean the ink that gets into the corners.      Once you peel away the tape what's left is really easy to clean.
Why do you use Yellow UV safety lamps?      There are clear sleeves that should be much brighter and still do the job.
We have a much simpler set than yours, we wash and coat manually.

[jsheridan]

Maxie,
This layout should suit you well.

[jsheridan]

We are remodeling our screen room currently, so I posted current, and work in progress, although that isn't exactly how it will be since we didn't want to move plumbing.

I see to much screen handling and getting them between rooms.

Incorporate pass through walls between the rooms, ventilate them as a chamber, and your drying problems will go away. You'll also spend 50% less of your time moving screens around as the walls between the rooms are your screen storage areas.

The room with the reclaim.. that is a 100% wet room and sealed off from the middle room. no walk through doors, tight closing doors on the wet into dry cabinet from reclaim so you don't contaminate the 2nd room dry air where all of the screen stretching, coating, layup and drying take place before the 3rd room exposes, develops and preps for print.