Here at Superior Ink, we’ve had our fair share of these moments, especially when someone asks, "Wait, there are different kinds of screen printing?"
If you’ve ever found yourself in that situation, perhaps too embarrassed to admit you’re not up to speed on screen printing techniques, don’t worry—we've got you covered.
We’re excited to walk you through three popular screen printing methods and explain which methods achieve exceptionally sustainable results.
Plastisol printing is the original giant in the screen printing world. The ink is easy to work with and dries quickly without needing water as part of the process.
Plastisol is very popular for its ability to be layered to create a more dimensional print, especially for its stand-out performance on dark garments. Because plastisol is made from plastic, it is moldable and versatile. Often, the garment that it is printed on loses breathability and has a thicker hand feel. It can be used to print on a variety of materials and surfaces that water-based and discharge inks aren't able to be used for.
However, it’s not without its flaws—plastisol is made from PVC and phthalates, harmful to both human health and the environment.
While some companies have moved to phthalate-free plastisol inks and those with reduced metal content, it’s a step towards sustainability but not the pinnacle.
Another big aspect to consider in the area of sustainable printing and inks is the longevity of the print. While it may be a quick process to get plastisol printed and out the door, how long that apparel remains in circulation is paramount.
Plastisol is known for cracking, bunching, and getting worn-looking far quicker than other printing methods. Even feeling gooey when worn in warm weather. While the colors often are vibrant throughout the life of a plastisol print, the print itself doesn't last the life of the garment. Because of this, the garment is often discarded much faster.
We always say that the longest-lasting garment is the most sustainable. Although the most common method in the industry, plastisol isn't the best screen printing method for all-around sustainability.
As we continue our exploration of screen printing methods, let's talk about the gentler side of the spectrum: water-based inks. Known for their incredible softness and minimal impact on the fabric's feel, these inks are a favorite among those looking for comfort and sustainability. Unlike their plastisol counterparts, water-based inks do not sit on top of the fabric; instead, they soak into it, which eliminates the heavy 'hand' that plastisol prints can produce.
These inks are not only softer but also healthier for our planet. They steer clear of harmful chemicals like PVC and phthalates, aligning perfectly with a more eco-conscious approach. However, they're not without their challenges. Water-based inks tend to dry quickly, which can clog screens if not managed properly. It requires a careful and skilled hand and a well-ventilated workshop to prevent the build-up of fumes and ensure a safer environment for the workers.
For water-based printing, dryers are the last step of the process to cure the print and set the ink. Although this can add to the carbon footprint of the printing process, we are always staying on the cutting edge of running energy-efficient dryers and curing the garments only as much as needed.
To boost the eco-friendly profile of water-based inks, opting for those derived from renewable resources is a step in the right direction. This method not only reduces the carbon footprint but also promotes a healthier production environment.
Next up is discharge printing, a unique technique that works its magic by removing the dye from dark fabrics and replacing it with the desired ink color. This process results in vibrant, eye-catching prints that maintain a very soft hand-feel, making the print actually part of the fabric itself.
Discharge printing is especially effective on 100% cotton, which is perfect for those who love natural fibers. However, its use is limited on synthetic blends, which can be a drawback for some. While discharge inks reduce the need for multiple layers of ink, thus conserving materials and reducing weight, they come with their own set of environmental considerations. Many discharge inks contain formaldehyde, a chemical that raises significant health and environmental concerns.
To navigate these challenges, opting for formaldehyde-free discharge inks is a responsible choice. Additionally, implementing proper waste disposal methods is crucial to minimizing the ecological footprint of this printing method.
Overall discharge printing is a great method that results in a high-quality print that lasts the entire lifespan of the garment, and if it fades, it fades evenly with the fabric.
At Superior Ink, we pride ourselves on crafting sustainable merchandise that not only represents your brand but also honors our planet. Each piece that leaves our shop carries a message of commitment—to do right by the earth that makes all our creations possible.
So, if you are about to embark on a printing project and find yourself flooded by all the information about "green" options, let us help you cut through the noise. We source all sustainable blanks, meaning that your project is on the right track from the get-go. Our team will walk you through the entire design process, choosing the printing method that best brings your vision to life while honoring your values.
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