Screen Printing Equipment & Setup
Essential Equipment
| Equipment |
Size/Type |
Price Range |
Purpose |
Skill Level |
| Screens |
110-305 mesh |
$15-$50 each |
Image transfer |
All levels |
| Squeegees |
6”-18” wide |
$10-$40 each |
Ink application |
All levels |
| Emulsion |
Photo emulsion |
$20-$60/quart |
Screen coating |
Intermediate |
| Transparency Film |
8.5”x11” to 13”x19” |
$0.50-$2/sheet |
Stencil creation |
All levels |
| Exposure Unit |
UV light box |
$150-$2,000 |
Screen exposure |
Intermediate |
| Washout Booth |
Spray booth |
$300-$1,500 |
Screen cleaning |
Professional |
| Press |
Manual/Auto |
$100-$50,000 |
Print registration |
All levels |
| Drying Rack |
Conveyor/Static |
$200-$10,000 |
Ink curing |
All levels |
Screen Mesh Specifications
| Mesh Count |
Thread Diameter |
Ink Deposit |
Best Applications |
Detail Level |
| 110 mesh |
Coarse |
Heavy |
Glitter, puff, specialty inks |
Low detail |
| 156 mesh |
Medium-coarse |
Heavy |
Opaque colors, white ink |
Medium detail |
| 200 mesh |
Medium |
Medium |
Standard plastisol, water-based |
Good detail |
| 230 mesh |
Medium-fine |
Medium-light |
Fine detail, halftones |
High detail |
| 280 mesh |
Fine |
Light |
Process colors, fine text |
Very high detail |
| 305 mesh |
Very fine |
Very light |
Four-color process, photographic |
Extremely high detail |
Press Types & Capacity
| Press Type |
Stations |
Price Range |
Production Rate |
Skill Level |
Best For |
| Manual Tabletop |
1-4 colors |
$100-$800 |
20-50 pcs/hour |
Beginner |
Small runs, samples |
| Manual Carousel |
4-8 colors |
$800-$5,000 |
50-150 pcs/hour |
Intermediate |
Medium runs, multi-color |
| Semi-Auto |
6-12 colors |
$5,000-$20,000 |
150-400 pcs/hour |
Advanced |
Large runs, consistency |
| Automatic |
8-16 colors |
$20,000-$100,000 |
400-1,200 pcs/hour |
Professional |
Mass production |
Ink Types & Applications
Plastisol Inks
| Ink Type |
Cure Temp |
Opacity |
Durability |
Price/Quart |
Best For |
| Standard Plastisol |
320°F (160°C) |
High |
Excellent |
$25-$40 |
General printing, dark garments |
| Low-Cure Plastisol |
280°F (138°C) |
High |
Excellent |
$30-$45 |
Heat-sensitive fabrics |
| High-Opacity |
320°F (160°C) |
Very High |
Excellent |
$35-$50 |
White on dark, bright colors |
| Stretch Plastisol |
320°F (160°C) |
Medium |
Good |
$40-$55 |
Athletic wear, spandex |
| Puff Plastisol |
320°F (160°C) |
High |
Good |
$45-$60 |
Raised texture effects |
| Glitter Plastisol |
320°F (160°C) |
Medium |
Good |
$50-$70 |
Decorative effects |
Water-Based Inks
| Ink Type |
Cure Temp |
Hand Feel |
Durability |
Price/Quart |
Best For |
| Standard Water-Based |
300°F (149°C) |
Soft |
Good |
$20-$35 |
Light garments, vintage look |
| Discharge Ink |
320°F (160°C) |
Very Soft |
Good |
$35-$50 |
Removing dye, soft prints |
| Pigment Ink |
320°F (160°C) |
Soft |
Very Good |
$25-$40 |
Eco-friendly, vibrant colors |
| Acrylic Ink |
Air dry/heat |
Soft |
Fair |
$15-$25 |
Posters, paper, fabric |
Specialty Inks
| Ink Type |
Special Properties |
Cure Requirements |
Price/Quart |
Applications |
| Metallic |
Reflective finish |
320°F (160°C) |
$60-$80 |
Premium apparel, logos |
| Glow-in-Dark |
Phosphorescent |
320°F (160°C) |
$70-$90 |
Novelty items, safety gear |
| Reflective |
Light-reflective |
320°F (160°C) |
$80-$120 |
Safety apparel, sports gear |
| Crackle |
Textured finish |
320°F (160°C) |
$50-$70 |
Vintage effects, distressed look |
| Foil Adhesive |
Foil application |
320°F (160°C) |
$40-$60 |
Luxury finishes, metallic effects |
Screen Preparation Process
Emulsion Application
| Step |
Process |
Time Required |
Temperature |
Humidity |
| Degrease Screen |
Scrub with degreaser |
5-10 min |
Room temp |
Any |
| Dry Screen |
Air dry completely |
30-60 min |
Room temp |
<50% |
| Coat with Emulsion |
Smooth, even coating |
5-10 min |
Room temp |
<50% |
| Dry Coated Screen |
Dark room drying |
2-24 hours |
70-80°F |
<50% |
| Expose Screen |
UV light exposure |
5-20 min |
Room temp |
Any |
| Washout |
Cold water spray |
5-15 min |
Room temp |
Any |
| Dry Exposed Screen |
Air dry |
30-60 min |
Room temp |
Any |
Exposure Times by Emulsion
| Emulsion Type |
Light Source |
Distance |
Exposure Time |
Washout Window |
| Dual-Cure |
500W Halogen |
18” |
12-18 min |
2-5 min |
| Dual-Cure |
LED UV |
18” |
3-8 min |
2-5 min |
| Photopolymer |
500W Halogen |
18” |
8-15 min |
1-3 min |
| Photopolymer |
LED UV |
18” |
2-6 min |
1-3 min |
| Diazo |
500W Halogen |
18” |
15-25 min |
5-10 min |
| Diazo |
LED UV |
18” |
5-12 min |
5-10 min |
Printing Techniques & Settings
Squeegee Specifications
| Squeegee Type |
Durometer |
Blade Edge |
Best For |
Lifespan |
| Soft (60-70 Shore) |
60-70 |
Rounded |
Heavy ink deposits, rough surfaces |
5,000-10,000 prints |
| Medium (70-80 Shore) |
70-80 |
Square |
General printing, most applications |
10,000-20,000 prints |
| Hard (80-90 Shore) |
80-90 |
Sharp |
Fine detail, thin ink deposits |
15,000-30,000 prints |
| Triple Durometer |
70-90-70 |
Composite |
Professional printing, consistency |
20,000-40,000 prints |
Printing Parameters
| Parameter |
Light Garments |
Dark Garments |
Fine Detail |
Heavy Coverage |
| Squeegee Angle |
45-60° |
45-60° |
75-90° |
45-60° |
| Pressure |
Light-Medium |
Medium-Heavy |
Light |
Medium-Heavy |
| Speed |
Medium-Fast |
Medium-Slow |
Slow |
Medium-Slow |
| Flood Stroke |
Light |
Medium |
Light |
Medium |
| Print Stroke |
Medium |
Heavy |
Light-Medium |
Heavy |
| Off-Contact |
1-3mm |
1-3mm |
1-2mm |
2-4mm |
Fabric & Substrate Compatibility
Common Garment Types
| Fabric Type |
Fiber Content |
Ink Compatibility |
Cure Temperature |
Special Considerations |
| 100% Cotton |
Cotton |
All ink types |
320°F (160°C) |
Excellent ink absorption |
| Cotton/Poly Blend |
50/50 blend |
All ink types |
280-300°F |
Medium absorption |
| 100% Polyester |
Polyester |
Low-cure plastisol |
280°F (138°C) |
Dye migration risk |
| Tri-Blend |
Cotton/Poly/Rayon |
Water-based preferred |
300°F (149°C) |
Soft hand required |
| Performance Fabrics |
Synthetic blends |
Stretch inks |
280°F (138°C) |
Moisture-wicking properties |
| Fleece |
Cotton or blend |
Heavy deposit inks |
300-320°F |
Thick fabric considerations |
Substrate Preparation
| Substrate |
Pre-Treatment |
Adhesive |
Curing Method |
Post-Treatment |
| T-Shirts |
Pre-wash optional |
Spray adhesive |
Heat tunnel/press |
None required |
| Hoodies |
Pre-wash recommended |
Spray adhesive |
Heat tunnel/press |
None required |
| Tote Bags |
Iron flat |
Spray adhesive |
Heat press |
None required |
| Posters |
None |
Vacuum table |
Air dry |
UV coating optional |
| Stickers |
None |
None |
UV cure |
Die cutting |
| Cardboard |
None |
None |
Air dry |
Coating optional |
Quality Control & Troubleshooting
Common Print Defects
| Problem |
Cause |
Solution |
Prevention |
| Pinholes |
Contaminated screen |
Clean screen, new emulsion |
Proper screen cleaning |
| Bleeding |
Emulsion breakdown |
Harden emulsion, new screen |
Proper exposure time |
| Poor Coverage |
Insufficient ink |
More passes, check squeegee |
Proper ink viscosity |
| Blurred Images |
Screen movement |
Secure screen, check registration |
Proper press setup |
| Ink Bleeding |
Wet ink smearing |
Reduce ink, faster cure |
Proper ink viscosity |
| Cracking |
Over-cured ink |
Reduce cure time/temp |
Temperature monitoring |
| Poor Adhesion |
Under-cured ink |
Increase cure time/temp |
Proper curing process |
| Mesh Marks |
Wrong mesh count |
Use finer mesh |
Proper mesh selection |
Curing Guidelines
| Ink Type |
Cure Temperature |
Cure Time |
Test Method |
Undercure Signs |
| Plastisol |
320°F (160°C) |
60-90 seconds |
Stretch test |
Ink cracks when stretched |
| Water-Based |
300°F (149°C) |
90-120 seconds |
Rub test |
Ink rubs off easily |
| Discharge |
320°F (160°C) |
60-90 seconds |
Wash test |
Colour doesn’t discharge |
| Low-Cure |
280°F (138°C) |
45-60 seconds |
Stretch test |
Ink cracks when stretched |
Business Applications & Pricing
Production Costing
| Cost Category |
Per Screen |
Per Shirt |
Notes |
| Screen Setup |
$15-$35 |
$0.50-$2.00 |
Depends on run size |
| Ink Cost |
$2-$8 |
$0.15-$0.75 |
Depends on coverage |
| Emulsion/Chemicals |
$3-$8 |
$0.10-$0.30 |
Per screen use |
| Labor (Setup) |
$20-$50 |
$0.75-$3.00 |
Depends on complexity |
| Labor (Printing) |
N/A |
$0.50-$2.00 |
Per piece |
| Garment Cost |
N/A |
$2-$25 |
Varies by quality |
| Total Cost |
$40-$101 |
$3.90-$33.05 |
Before markup |
Minimum Order Quantities
| Run Size |
Setup Cost/Piece |
Recommended Pricing |
Profit Margin |
| 1-11 pieces |
$8-$15 |
$25-$40 |
50-75% |
| 12-23 pieces |
$4-$8 |
$18-$28 |
60-80% |
| 24-47 pieces |
$2-$4 |
$12-$20 |
65-85% |
| 48-99 pieces |
$1-$2 |
$8-$15 |
70-90% |
| 100-499 pieces |
$0.50-$1 |
$6-$12 |
75-90% |
| 500+ pieces |
$0.25-$0.50 |
$4-$8 |
80-95% |
Market Opportunities
| Market Segment |
Order Size |
Price Range |
Repeat Business |
Competition |
| Custom T-Shirts |
1-50 pieces |
$15-$35 |
Medium |
High |
| Corporate Apparel |
25-500 pieces |
$8-$25 |
High |
Medium |
| Sports Teams |
12-100 pieces |
$12-$30 |
High |
Medium |
| Event Merchandise |
50-1000 pieces |
$6-$20 |
Low |
High |
| Band/Artist Merch |
25-200 pieces |
$10-$25 |
Medium |
Medium |
| Promotional Items |
100-5000 pieces |
$4-$15 |
High |
Low |
| Fashion Brands |
50-500 pieces |
$12-$40 |
High |
Low |
| Non-Profit Orgs |
25-300 pieces |
$8-$20 |
Medium |
Low |
Startup Costs & Equipment
Initial Investment Breakdown
| Equipment Level |
Hobby Setup |
Small Business |
Professional |
| Press |
$100-$500 |
$800-$3,000 |
$5,000-$25,000 |
| Screens (6) |
$90-$180 |
$150-$300 |
$300-$600 |
| Squeegees (3) |
$30-$60 |
$60-$120 |
$120-$300 |
| Emulsion & Chemicals |
$50-$100 |
$100-$200 |
$200-$500 |
| Exposure Unit |
$150-$300 |
$300-$1,000 |
$1,000-$5,000 |
| Washout Booth |
DIY $50 |
$300-$800 |
$800-$3,000 |
| Drying Equipment |
$100-$200 |
$500-$2,000 |
$2,000-$15,000 |
| Ink Starter Kit |
$150-$300 |
$300-$800 |
$800-$2,000 |
| Misc Supplies |
$100-$200 |
$200-$400 |
$400-$800 |
| Total Investment |
$820-$1,840 |
$2,710-$8,620 |
$10,620-$52,200 |
Monthly Operating Costs
| Expense Category |
Hobby |
Small Business |
Professional |
| Ink & Chemicals |
$50-$100 |
$200-$500 |
$500-$1,500 |
| Screens & Squeegees |
$20-$40 |
$100-$200 |
$200-$500 |
| Utilities |
$25-$50 |
$100-$300 |
$300-$800 |
| Rent |
$0 |
$200-$1,000 |
$1,000-$5,000 |
| Insurance |
$0 |
$100-$300 |
$300-$800 |
| Marketing |
$25-$50 |
$100-$500 |
$500-$2,000 |
| Total Monthly |
$120-$290 |
$800-$2,800 |
$2,800-$10,600 |
Maintenance & Best Practices
Daily Maintenance
| Task |
Frequency |
Time Required |
Importance |
| Clean Screens |
After each use |
10-15 min |
Critical |
| Store Squeegees |
After each use |
2-5 min |
High |
| Cap Ink Containers |
After each use |
1-2 min |
High |
| Clean Work Area |
Daily |
15-30 min |
Medium |
| Check Equipment |
Daily |
5-10 min |
High |
Weekly Maintenance
| Task |
Time Required |
Importance |
Notes |
| Deep Clean Screens |
30-45 min |
Critical |
Remove all ink residue |
| Reclaim Screens |
45-60 min |
High |
Remove emulsion completely |
| Squeegee Sharpening |
15-30 min |
Medium |
Maintain sharp edges |
| Inventory Check |
20-30 min |
High |
Reorder supplies |
| Equipment Lubrication |
10-15 min |
Medium |
Moving parts only |
Screen Reclaiming Process
| Step |
Chemical |
Time |
Temperature |
Notes |
| Ink Removal |
Ink degrader |
5-10 min |
Room temp |
Scrub thoroughly |
| Emulsion Removal |
Emulsion remover |
10-15 min |
Room temp |
Let chemical work |
| Degreasing |
Degreaser |
5-10 min |
Room temp |
Remove all residue |
| Final Rinse |
Clean water |
2-5 min |
Room temp |
Complete removal |
| Drying |
Air dry |
30-60 min |
Room temp |
Completely dry |
This cheatsheet provides comprehensive information for screen printing success. Always follow safety protocols when working with chemicals and ensure proper ventilation in your workspace.