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How To Design A Screen Making Department – Textile Screen PrintersWilliam ShorterCPS Technical Sales Executive/Product Manager
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!
The Good And The Bad!
A Recipe For Disaster!Exhaust fan not workingShelves not fixed to the wallOpen containerUnlabelled containersNo glovesNo gogglesNot waterproofed electricsTrip hazardsNo safety shoesSlip hazardUntidy
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?
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
Screen making is separated into two areas: screen cleaning and screen makingScreen cleaning is dirty and screen making is clean
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
Use white light in the screen cleaning area as it is much easier to examine a screen under white light than yellowAlways use yellow safe lights in the screen making area
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
Dirty screens are brought in from the production areaIf you have a standard screen size, use mobile racking which can be wheeled in and outScreens are very expensive – do not leave them leant up against a wall as they will become damaged
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
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
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
The first step is to remove the old ink off the screenUse a dedicated screen cleaning booth for thisMake 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
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
Use a separate screen cleaning booth for stencil removalMake sure there is both a low pressure water spray as well as a high pressure gun – Never rinse off chemicals with a pressure gunThe booth should be equipped with an exhaust fan especially if haze removers are usedUse a white back light to inspect the screensThis area will become wet – use non slip mats in front of the booth
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
The final stage in cleaning is degreasingTOP TIP: Use an in-line water filter to remove dirt from the water supply
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
To reduce contamination fit double sided vertical drying cabinets between the two areasThis way screens can be loaded into the dryer from the cleaning area and unloaded from the screen making area
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
The screen making area should be a controlled cleanliness area to reduce contaminationTop Tip for the best screens: Operators should wear ‘clean room’ clothing as most contamination comes from peopleIf you can maintain a positive pressure in the room this will limit the amount of dust that comes in
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
Try to reduce the number of times that the door has to be opened and make sure it is a ‘self closing’ doorPosition 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
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
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 screenCoated screens can be stored vertically once they are dry
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
A HEPA filter fitted to the air conditioning unit will provide a dust free environmentThe ideal conditions are 55% Relative Humidity and 20°cTOP TIP: use the CPS safelight indicator to test your safelights
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
Reduce UV reflections by painting the exposure area matt blackMake sure there is no light spillage from the exposure unit which could fog coated screens, or injure the operator
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
Fit an in-line water filter to the washout sprayUse both a strong shower spray and a pressure gun for the washoutThe washout booth must be fitted with a back light for ease of inspectionFit a non-slip mat in front of the washout as this area will become wet
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
After washout, the screens can be dried verticallyUse warm air to ensure screens are fully dry before printing
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
Once dry the screens can be spotted out before printingA near vertical inspection light box is easier to use for large screens
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Sten
cil
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer
Deg
reas
ing
&
Haz
e re
mov
al
Non
-slip
mat
Scr
een
clea
ning
ch
emic
als
stor
age
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Dip
Tan
k A
ll-In
-O
ne
Verti
cal r
ack
for
dirty
scr
eens
Pressure
washer Non
-slip
mat
Screen cleaning chemicals storage
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
PPE Storage
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Was
hout
boo
thW
asho
ut b
ooth
Dip
tank
Dip
tank
PP
E S
torage
Vertical loading station
Pressure
washer
Sten
cil r
emov
al
Non
-slip
mat
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Ink
rem
oval
Screen cleaning chemicals storage
Vertical unloading and drying station
Washout booth
PPE Storage
Vertical loading station
Pressure
washer
All-
in-o
ne in
k an
d st
enci
l rem
oval
Non
-slip
mat
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Screen cleaning chemicals storage
Vertical unloading and drying station
Washout booth
PPE Storage
Vertical loading station
Pressure
washer
All-
in-o
ne in
k an
d st
enci
l rem
oval
Non
-slip
mat
Washout booth
Non-slip mat
Tack
mat
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 areaYellow safelight
Self closing swing door
Vertical light box for retouchingWork flow direction
In-line water filter
Clean room
clothing
Coated screen storage
Scre
en c
lean
ing
area
Screen cleaning chemicals storage
Vertical unloading and drying station
Washout booth
PPE Storage
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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