Screenprint

Screenprint Overview

G54.com has a full screenprint facility capable of printing up to 10 color designs with 2 flash stations. Our facility has (2) 12 head automatic presses (1) 10 head and (1) 4 head manual press. With our arsenal of presses we are capable of printing up to 70,000 shirts a day.

Our in house facility allows us to monitor and control the screening process from start to finish.

  • Creating art
  • Separating film positives
  • Burning screens
  • Printing apparel
  • Finishing services
  • Delivery
Our 50,000 sq foot warehouse with rows of blank shirts
Shirts Counted, piled and waiting to be printed
 

Able to create any color from our 16 color weight based mixing station

Screenprint Colors

We offer a wide selection of plastisol inks. With over 130 premixed colors we can accurately reproduce your designs and styles.

If an exact color match is needed we can mix any of the pantone formulated colors with our 16 color weight based mixing station.

Specialty Processes

Some shirt designs need that little extra kick to help them stand out from the rest. G54.com Design Apparel offers 5 specialty processes in addition to our library of inks.


The touch and look of puff is a
nice addition

Puff Ink

Add dimension to your design with Puff. This additive causes the plastisol ink to rise up slightly like a marshmallow and can be mixed with any color in the Pantone Matching System. If you do not have a Pantone color guide, we can match your files to the closest available swatch.

 

The gray background is created
with discharge ink

Discharge Ink

Bring back the natural cotton color. Discharge inks remove the dyes used to color cotton t-shirts, thus creating an image on a medium to dark shirt without technically using ink. This creates a very soft, natural feeling image.

 

Metallic Inks add that subtle
sparkle in the right light

Metallic Inks

Several metallic colors give your design a subtle metallic sheen that catches the right light.

 

When more sparkle is needed
use glitter inks

Glitter Ink

With small flakes of reflective glitter printed on top of any color specified, this highly reflective technique will surely turn some heads.

 

Oversized Print


Bigger is sometimes better

Printing larger than the norm makes a bold statement. Printing 25 inches from shoulder to shoulder is a process that can gain value in buyers eyes. To go big only costs an additional $3.00 on top of our normal screen printing fee.

 

Imprint Guidelines

With dozens of different shirt companies, cuts, sizes, and styles of shirts, it is important to look closely at all shirts in your order to determine how the imprint will fit on the smallest to the largest shirt. There are 3 different shirt table sizes that we print on.

When combining regular cut adult shirts with youth shirts and or womens cut shirts our policy is to print art work as large as we can to fit on the smallest shirt. We will then print that same art work on all other shirts in the order. The result is a large imprint on the small shirts and a small print on the biggest shirts. For the design to look and sell best, it may be best to write up two separate orders (1) for small and medium shirts and (1) for large, XL and XXL shirts.

 

Adult T-Shirt Sizes

Based on a regular cut Gildan adult shirt, all shirts sizes from S-XXL will
fit on our regular size print tables (15 inches X 21inches)

 

T-Shirt Sizes

Based on a Gildan youth shirt, all shirts sizes from XS-XL will fit on our youth size print tables. (11 inches X 21inches)

 

Toddler/Baby T-Shirt Sizes

Based on a Gildan toddler shirt, all shirts sizes from 2T-4T will fit on our youth size print tables. (11 inches X 21inches)

 

Print Locations

Decorating apparel is an individual and unique process. Being creative with size and placement of designs can make all the difference in how well a shirt will sell. Refer to the chart below to clearly communicate where you want your imprint to be placed.

 

Art Requirements

Printing quality shirts starts with quality art. Most images consist of 1000’s of different colors while silkscreen tries to simplify an image to just a handful of colors. There are 2 types of art files for printing shirts:

 

Vector Art

Vector is a digital art format that comprises a series of mathematical equations which create and reproduce sharp crisp lines and colors no matter how large or small an image is reproduced. It is the preferred art file for creating shirts, because what you send to us is exactly what you will get back and it is a simple format for preparing and printing files.

Raster Art

 

Monitors display images as pixels or a grid of small dots. The more pixels or dots per inch, the more detailed an image. Raster art must be sent at higher resolutions (300 dpi) to avoid the risk of your images appearring to be jagged when enlarged or details disapearring when the art is reduced.

 

Submitting Art

Work with a salesperson before submitting artwork for t-shirts. Email vector based art (if possible) Common vector file extensions (.ai, .pdf, .eps)

1. Design Using Spot Colors:

When creating art use PMS spot colors. Pantone® is a universal color matching system used all over the world and helps printers to match the exact colors you design with. Most design programs have color swatch toolboxes that allow you to design with Pantone® Colors.

2. Outline Fonts:

Make sure any font (type) used is outlined. Your computer uses font files so you can type any letter but if you email it we will not be able to see the font you intended.

3. Submitting Raster Art:

(jpg, tif, gif) Artwork must be submitted at actual print size with a file resolution of 150-300 dpi (dots per inch).

Recreating Art

If the customer does not have the required art necessary to create a clean print, small & low resolution images, or scanned art (from a business card for example), our art department will need to recreate the file in the proper format so we can create a quality screenprint. Our art fee is $1.00 a minute. Time varies depending on the art. Email artwork to a salesperson and we can get an estimate to you on how much time will be required to recreate your artwork.

Pricing Minimums

Contact a salesman for current prices and minimums.

Extra print locations, specialty print applications, basic set up fees, finishing fees, and rush charges can be calculated by your salesperson since every job is unique.

Silkscreen Process


Create art in digital form

Create Art

All art whether it was created digitally or by hand, must be simplified and prepared by our artists to be separated.

 

4 color design, film positives

Separate Art

Life is full of millions of colors; unfortunately silkscreen is limited to a handful. Depending on the type of art, our artists will put each color on its own film positive which will help in the creation of our screens.

 

Position & Expose Art

Tightly and evenly pulled screen mesh is attached to a strong light metal frame. These screens are then covered with a light sensitive emulsion. This is done in a special room that uses a yellow colored light. The film positives created by the art department are positioned on the frames. The screens are then exposed to a bright light for a certain amount of time. Once exposed properly, this area (that was not blocked by the film positive) hardens, and the area that was not exposed to light will wash out of the screen in the next step.

Position art on prepared silkscreen frames
Expose light sensitive emulsion
 

Exposed and washed screen frames drying

Washed Out Stencil

Once the emulsion on the screens has been exposed, the stencil is then sprayed by a high powered water spray that washes away the unexposed emulsion. The screens are then dried and taped before going into production.

 

Production Floor


Ink being pushed through stenciled mesh

Once designs hit the production floor they are sorted by priority. Each job is connected to certain product and colors of apparel. The design is set up and registered so that each color prints exactly where it should. Designs are usually printed with a white underlay first which neutralizes the shirt color.

The white is then flash-dried so the other colors in the design will build on top of the underlay. Ink is pushed through each mesh screen by a pressure driven squeegee. After the design is printed it is sent through a dryer at a certain temperature for a certain time period drying the ink permanently to the shirt. Product is then moved to the finishing area.

Multiple jobs waiting to be screened
14 Station / 12 Color
 

Reclaim Screens


Multiple jobs waiting to be screened

Once a job has printed all reserve inks are returned to the canister, and screens are cleaned and reclaimed. The mesh is reopened and once the screens are dry the process starts all over again. It’s the circle of life at G54.com Design Apparel.