Last week, Jimmy rushed into my office with a print and told me that the film should be remade, or at least it should be replaced by a wire mesh. He sat down in his chair and put the prints on my desk and said, "The subtle differences between the pictures." Then he told me about the details of the operation: First, use 125 mesh screens. Printed in white; after rapid heat treatment, PMS 286 was used to match the values ​​of the 230 mesh screen. Pure dark blue was printed on some white solids, and uniform white was printed on the black part of the shirt. In the heavy-duty cotton T-shirts, the white printing effect is good, but the blue is getting worse after printing more than a dozen pieces. When it was printed to less than 4 dozens, it was time to shut down and scrub the screen. The job can be reprinted. However, only 48 pieces can be printed at a time. At that time, at the request of Jimmy, Sam and Dave of the Department of Silkscreen Printing appeared at the door of my office. Actually they do not really need them. I let them stay and listen to my explanation.
The problems encountered at the time were: the extremely low plastic viscosity of blue, plus the temperature increase caused by rapid drying. The blue ink is further reduced in viscosity. The plastic viscosity is the flow characteristic of the ink at the time of printing under the pressure of the squeegee and the squeegee. In the beginning, the consistency of the ink is not fixed. As the ink is scratched on the screen (to be transferred to the shirt through the screen), the ink is also diluted. The situation we encountered at the time was that the ink became thin and it was impossible to reproduce the subtle levels. Newcomers often think that the problem lies with the screen, the film, or other links that may be thought of at that time. But most problems are caused by ink, and the higher the production temperature, the greater the problem.
The problem also involves printing. The weight of the blue pigment is not very light, the oil absorption is strong, and the shape is like a needle (the pigment particle is long and thin). When the PMS color matching parameter is 286, the amount of pigment input is quite large. Due to the pigment's own characteristics, the ink has a large fluidity. Furthermore, overprinting pure blue on a white background will reveal all the flaws.
Scrubbing the wire mesh is only a symptom, not a permanent cure. Although there is indeed dirt underneath the screen, what helps (at least temporarily) to solve the problem is the time for scrubbing the screen. It allows the ink to return to a more appropriate printing temperature and viscosity.
At the time we recorded the time and temperature used for the white and blue colors. Our suppliers also have the ability to improve the ink so that it does not become too thin, to ensure that we get a stable and qualified print quality. After listening to the explanation, Sam and Dave went back to work and happily made another set of screens.
"We can't deliver on time at this speed, and we can't speed up production." Carlos's face was sweating. It's not because of the sweat that fills the press, but Carlos's sweat. He worried that he could not deliver on time at a rate of 35 dozen per hour. To ensure on-time delivery, he intends to arrange for the second shift to be overtime. Together with his colleagues, he tried all the dimensions of the squeegee he could think of, the top angle, the height, the shape, and all the angles that could be placed. They adjusted the distance between the screen and the substrate several times, even at a very small distance. Finally they used thinner to reduce the viscosity of the ink. However, the ink loses opacity after passing through the mesh. I said to Carlos that the problem was with ink. He was very surprised.
Next, I first checked the calibration technical requirements of the printing press and the actual adjustment of the printing press. There is no problem in the distance between the screens. The front of the squeegee is pointed and the embossing angle is 80 degrees, which is in line with the standard. The fine mesh holes we use (large screen tension and small screen distance) are best suited for fast printing. The screens used meet the technical requirements of tension, coating, exposure and development. So ink is the only factor that should be considered.
The ink in the container has a relative viscosity. When we heat the ink on the press, its plastic viscosity is still high. The viscosity of the ink was not low enough at the time and it was not suitable for high-speed printing. We know that the independent characteristic of tack is determined by the mixing state of the plasticizers of the resin. The viscosity of the ink is too high in relation to the following ink manufacturing processes: overheating, poor dispersion of resin and aged plasticizers (plastic resin absorbs all of the plasticizer), improper use of fillers. The above link is usually related to the ink production speed or raw material cost.
So we used the ink distribution method to solve the speed problem. First, we purchased a low-viscosity, high-viscosity ink from the manufacturer. Then we added an appropriate amount (about 10%) of the above ink to the ink we used. In this way we can keep the viscosity of the ink constant (which cannot be achieved only with thinner) and the opacity is no longer a problem. The quality of the job is good. Later we switched to inks with suitable properties: high-viscosity, low-viscosity inks. "Seven screens, dried seven hours, the ink is still not printed." Dan intends to return the color ink. It is a specially formulated color ink, but it is particularly difficult to print on the substrate. Dan wanted to seize the time to deploy a very similar ink as a substitute ink. But I remind him not to forget that the red ink is used to print the customer's company logo. In addition the formulated ink does not give very close results. (To be continued)

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