Purpose-built Print (Screen Printing)

Demand for screen retrofits multiplies as printers look to satisfy process-savvy manufacturers.

by Jessica Millward, Associate Editor

WHILE THERE IS no easy-out clause when adopting a new print method, screen retrofits allow printers to make a significantly smaller leap of faith (and finance). And with manufacturers gaining awareness of its unique benefits, job-specific or brand-specific requests for screen will make the retrofit an even more appealing option.

Path of less resistance

Screen printing, in its nature, is a more niche-oriented process. As Gary Teeter, after market applications engineer for Mark Andy explains, "Printers likely to retrofit…are typically looking to expand production capabilities in order to produce very high-quality specialty labels or products, but want to test the waters before expending too much of their valuable time and money."

The impetus for expansion frequently comes from the printer's customer. As manufacturers learn to identify the type of look and feel they want for their packaging, specific requests for screen are on an upswing.

Ko-Pack Sales Director Gerry Nigg believes the addition of screen is very customer-driven, because, as he notes, "The Procter & Gambles, the Colgates, etc., are very smart, and they have educated themselves [about printing technologies]." He also cites the growing popularity of filmic substrates as a great spur for screen usage.

A screen retrofit allows printers to take smaller, sure-footed steps to screen capability. Tom Kirtz, president of Telstar Engineering, emphasizes the value of being able to simply enhance an existing press with a trained operator and an established investment in tooling.

Propheteer International VP Mike Polkinghorne agrees, suggesting, "Retrofitting a screen to an existing press might be the fastest way to bring a job in-house, and reduces the investment to get into the rotary screen marketplace." To make screen production that much easier, Propheteer's screen unit includes a sizable drip pan for catching spills, as well as a slide-out screen cartridge for off-press clean-up and set-up.

Gallus, too, has had its eye on making the addition of screen as painless as possible. Sales Manager Bob Yates describes how the Gallus EM280 now features new printing station bases which make the screen retrofitting process very simple. Also, letterpress printers looking to add screen printing to their Gallus R160s or R200s can bypass the retrofit altogether; the screen heads can be added onto the press as is.

Budget breakdown

Adding screen to a printer's roster can be done to match a range of budgets. As Polkinghorne attests, positioning the screen above a print station is the most economical option, but a self-standing screen module will yield better performance and is easier to operate. The costliest method, wherein screens are mounted on a rail system, provides greater flexibility but reduced print accuracy.

Depending on a press's particular brand and configuration, Teeter estimates the initial investment for the screen head (with a UV lamp system) could be relatively inexpensive. He warns, however, "If screen-making capability is required, another investment of $60,000 or more is needed. But this can be added at any time and is usually not recommended until the customer is very confident of the market."

Nigg advises looking at the total price picture before investing in the retrofit. Many potential screen printers think calculating cost is just a matter of tallying up the screen and screen head. "They often forget they have to get prepress equipment and they have to get wash-out materials," he states.

Another critical element of the screen retrofit equation is the type/price of screens themselves. Some more expensive screens can be re-used up to 15 times, notes Teeter, while more economical versions have a greater tendency to break.

Steve Gilbertson, Midwest sales manager for Kammann Machines, points out the new set of prepress specifications with screen. The basic film output facility easily handles these changes, he notes. He does remind printers, "The inks are more expensive simply because you're using more of them."

Aside from financials, Yates believes printers should consider two issues before investing in screen equipment: first, the availability of room on the press; and second, how easily a press can be adjusted to the equipment. This is especially true when screen equipment is added for one specific application.

Screening options

So what new looks are being achieved with screen retrofits today? Kirtz has noticed the practice of overprinting labels with text using thermochratic inks. "The thermochratic area changes from black to clear at a certain temperature," he says, "revealing whatever is printed." He has also witnessed more instances of rotary screen being used to block an image to produce one label that has both the primary image and the back image on it.

Teeter remarks on screen technology employed to apply a pattern adhesive. He states this method provides superior volume control as compared to an anilox roll, especially if high volumes are required.

Gilbertson has noticed screen in an increasing number of high-speed flexible packaging applications, as well as a number of shrink-sleeve applications. However, he comments, "Most packaging people aren't fully aware of [screen's] capabilities." Within the last 15 years, Gilbertson observes, there have been a huge number of screen installations in Europe. He predicts, "In America, it's just a matter of evolution."