March '15

For the Business of Apparel Decorating

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Page 87 of 118

20 1 5 M A RC H PRINTWEAR | 83 such as the ink costs to print on the films or the labor costs of mounting films or archiving them for reprints in the future. Ultimately, the numbers to consider are based on film costs and labor. A printer has to look at cost of manufacturing to calculate ROI. In many cases, businesses realize ROI in only a few months. INTEGRATION Integrating a CTS system can be challenging, and most people are resistant to change, even for the better. To integrate a CTS system, we must convert from an analog film-based workflow to a digital workflow. Without film, traditional proofing or review of film no longer exists. Prepress accuracy from the beginning is even more critical. Separators will now place images on templates directly on the screen, and proper placement will be determined at this stage. Everything we think we know about film and halftone configurations is al- most out the window. It takes real-world testing to dial in the settings of a CTS system in each environment. Halftone, stencil, and mesh combinations must be tested and printed for optimal results. Once dialed in, however, they don't change and can be repeated exactly. The voodoo used to massage each ex- posure and development can be avoided. Screens can be properly exposed and developed with high It takes real-world testing to dial in the settings of a CTS system. Once tested, production can begin, and the settings remain the same. TRADITIONAL FILM WORKFLOW PROCESS 1) Art Creation 2) Separation 3) Output to Film Positives 4) Align Film Positives on Carriers for Preregistration 5) Align Registered Film Positive to Screen 6) Place Screen and Film onto Glass 7) Draw Down Vacuum 8) Exposure 9) Remove Film From Screen 10) Develop Using Water 11) Dry 12) Inspect / Block Out and Tape Pin Holes 13) Align Screens to On-Press Fixture 14) Add Ink, Squeegees, & Flood bars 15) Test Print 16) Microregistration Adjustments 17) Tape off Registration Marks 18) Production Can Begin CTS WITH ON BOARD EXPOSURE WORKFLOW 1) Art Creation 2) Separation 3) Output Directly on Screen & Exposure 4) Develop Using Water 5) Dry 6) Align Screens to On-Press Fixture 7) Add Ink, Squeegees, & Floods 8) Test Print 9) Production Can Begin continued on page 111

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