The main factors affecting hand screen printing costs are the design complexity (number of colors and print locations), order quantity, garment type, and labor and setup costs. More colors and locations require more screens, increasing setup time and expense, while higher quantities spread fixed setup costs over more items, lowering the per-item price.
Design and production factors :
- Number of colors:
Each color requires a separate screen and separate ink application, so more colors directly increase costs.
Number of print locations:
More print locations (e.g., front and back) mean more screens, setup time, and labor, adding to the final cost.
Order quantity:
Setup costs are fixed. The more items you print, the lower the per-item cost becomes. Bulk orders are generally more cost-effective.
Complexity:
Complex designs with fine details or gradients can be more difficult and expensive to produce with screen printing compared to simpler designs.
Manual versus automatic:
Whether a shop uses a manual press or an automatic one can affect turnaround time and cost.
Flashing:
Using a flash cure unit between colors to prevent ink from bleeding can add to the cost.
- Material and garment factors
- Garment type:
The cost of the blank garment itself, including fabric type, brand, and quality, is a significant factor.
- Ink type:
The type of ink used can affect the final price. Specialty inks may cost more than standard options.
- Other considerations
- Setup and labor:
The time and effort involved in creating screens, mixing inks, and setting up the press are significant components of the cost.
Geographic location:
Printing shops in areas with higher operating costs may charge slightly higher prices.
Why are screen prints so expensive?
Screen printing is expensive initially due to setup costs, including screens, inks, emulsion, and labor for preparing designs. The more colors and complex designs, the higher the setup fees. However, once set up, it becomes extremely affordable per shirt, especially for larger orders.
How Does It Work?
- Design Creation. The first step in the process of screen printing is to create the design. …
- Selecting and Preparing the Screen. …
- Exposing the Emulsion. …
- Stencil Creation. …
- Preparation for Print. …
- Applying the Design. …
- Heat Curing & Finishing.
Factors Affecting Pricing Decisions
- Cost of production (materials, labor, overhead)
- Competitor pricing and market trends.
- Customer willingness to pay and sensitivity.
- Product value, brand reputation, and features.
- Company objectives—market share, profitability, or rapid growth
To reduce screen printing costs, optimize your workflow by improving efficiency, reducing waste, and cutting labor time through better setup and management. Focus on optimizing screen setup, minimizing ink usage, and using the lowest mesh count screen possible for your design and ink.
Improve workflow and efficiency
- Master screen setup:
Spend time on the initial setup, like proper off-contact and aligning registration marks, to prevent errors and misprints, which saves time and materials.
Use a vacuum bed:
This can help with more consistent and crisp screen exposure, saving time and potentially improving quality.
Invest in reusable frames:
Self-tensioning frames can make the process of tensioning screens faster and easier.
Minimize waste:
Before washing out your screens, let the emulsion soak to speed up the process. When printing multi-color designs, use tape to cover areas you are not printing on.
Streamline your process:
Develop a consistent and organized process for ordering, printing, and handling jobs. This will make you faster and more efficient over time.
- Optimize materials and ink
- Choose the right screen mesh:
Use the lowest mesh count screen possible that will still hold your design and work with your ink. Thicker inks, like some whites for polyester, require a lower mesh count.
Use the correct ink:
The right ink for the job will help reduce issues and make printing easier. For example, use a thick white ink designed for polyester to stop color bleed-through, and use the lowest mesh screen that can hold the design.
Consider your film:
If you are not printing a lot of film yourself, consider outsourcing it to a service provider to save money.
- Reduce labor costs
- Focus on efficiency:
The more efficient your process is, the less time you’ll spend on each print, leading to lower labor costs.
Take the time to get it right:
Instead of rushing, take the time to properly set up screens. This will prevent misprints and save you time in the long run.
Improve your skills:
Practice and experience will make you faster and more efficient at the core tasks of screen printing, which will help lower your costs.
Sincerely,