Ink 101: What is all this ink, anyway?


With all of the different technology in the garment and apparel decorating industry, it is easy to get lost in the midst of the hundreds of printers and inks available for use. From solvent to sublimation, the terminology can leave a lot of people confused. Having worked with a lot of these inks ourselves, we want to offer some clarity and break it down to a simplified description of each ink system and its pros and cons.

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Inkjet Laser –  Sublimation –  Solvent –  Direct-to-Garment

 

Aqueous Inkjet Inks

These inks are water-based, but most people know them as just regular inkjet inks. All office and professional inkjet printers come with this type of ink which is contained in cartridges with a certain pigment to water ratio which results in liquid ink. The ink is deposited on the paper during the printing process, and once finished printing, the water evaporates leaving only pigment on the paper. The four basic colors are CMYK (cyan, magenta, yellow and black) with some printers using additional colors. What is not as common knowledge is that there are two categories of inkjet inks: Dye-based and Pigment-based.

Dye-based inkjet inks are the most common inks that come with the average inkjet printer. The pigment is fully dissolved in water inside the cartridge.. These inks are technically not as ideal for heat transfer paper garment applications as they tend to run more easily under wet conditions, but are great for daily print jobs for your home or business such as documents, indoor displays, posters, or fine art photographic prints due to their vibrancy and true to color image reproduction.

Pigment-based inkjet inks, also sometimes called UV inks, have larger pigment particles that are insoluble and are suspended in less water,  which makes them more ideal for more waterproof solutions such as heat transfer papers for garment decorating, window/outdoor displays, posters, decals, photographic prints, etc. The prints do not run when they come in contact with water but can fade and break down over time after repeated washing (specifically with heat transfer papers) or prolonged outdoor exposure. They are UV-resistant which AAA_1919means they can be exposed to UV light while the colors remain stable. Due to the nature of these inks and the way the light reflects off the pigment particles, they sometimes appear more muted in vibrancy than dye-based. A lot of the Epson inkjet models, such as the workforce series (we use Epson WF-7010 printer), already come with pigment inks, but it is a good idea to double check with the manufacturer.

Note: These are not to be confused with “UV-curable inks”, which require exposure to a very strong UV light to be cured onto the media.

 

 

Aqueous Dye-Based Ink Aqueous Pigment Ink
PROS:
  • Lower Cost
  • Brighter/more vibrant print
  • More waterproof solution that will not run in contact with water
  • UV-resistant that promotes color stability when exposed to bright light
  • Great for heat transfer paper applications
CONS:
  • Not waterproof/may run in contact with water
  • Not UV-resistant/ may fade over time due to sunlight exposure
  • Can be prone to clogging if left to dry inside printer
  • Higher cost
  • Color may appear more muted/ not as vibrant as dye-based ink
  • Can be prone to clogging if left to dry inside printer

 


 

Laser Toner

The second most popular method for every day printing is laser printing which in fact does not use ink, but rather a very fine powder called “toner”. The toner is contained in large cartridges in the printer and is deposited on the paper through either laser or LED technology.  Then the paper runs through a fuser which uses heat to fuse the pigment in place. Most laser printers use the CMYK colors, but recent advances in technology now allow for select few printers to use white toner instead of black, such as our OKI 920WT and OKI 711WT models.

Toner, unlike most other types of inks, does not use liquid in any way which makes it a very waterproof solution, but is still prone to fading over time. Because toner requires heat to be permanently cured in place, for those who are in the heat transfer paper business, it is crucial to have a printer with fuser that runs no hotter than 350F or else the paper adhesive can melt and jam. This is also why the compatibility of papers and printers is difficult to guarantee and always requires testing to ensure the paper will run smoothly through the printer. With the market constantly growing, in recent years manufacturers have started building printers with heat transfers in mind. Our OKI printers have been tested and are warrantied with most of our heat transfer papers.

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PROS: CONS:
  • Waterproof
  • Requires little to no maintenance as toner does not clog
  • Faster print speed for high volume printing
  • Toner usually lasts longer
  • Costs significantly less per-print
  • Laser printers not compatible with all papers, especially some heat transfer papers
  • Higher cost for full color and photographic printers
  • Bulkier/larger cartridges and printers
  • Not always ideal for quality fine art prints

 


 

Dye-Sublimation Ink

Dye-sublimation ink, while also water-based, is a much different type of ink than other typical printing solutions. Sublimation ink is printed on special sublimation paper (similar in look/feel to thicker copy paper) which releases the ink once it is heat activated in the press, turning it from solid to gas while bypassing the liquid stage.

It is compatible with a select few existing small format printer models, such as the Sawgrass Virtuoso SG400 and SG800 printers, the Epson Artisan 1430, and the older Ricoh SG3110DN and SG7100DN. It is also available for some wide format Epson and Mutoh printer models for those who seek high production, larger printing and high cost savings (lower cost for ink overall). There are so few models available because it is a special ink that also requires specific color correction software, and that is available for these select printer platforms for greatest performance consistency. Older formulations of sublimation ink, such as those for Epson printers, have a higher water to dye ratio, which makes them more susceptible to drying up and clogging the nozzles if not used daily, but are the only small format inks that offer a bulk-system option for higher volume printing and lower cost. The newer Sublijet R and Sublijet HD inks for Ricoh and Virtuoso printers are reformulated into a gel-like substance, which uses less water, preventing clogs when printer is not being used daily, however only come in cartridges and are not available for a bulk system.

The process of sublimation transfer printing and pressing to a product is usually done at around 370-400F depending on the item and the process ends as soon as heat is no longer applied and item starts cooling down. Sublimation ink dyes the garment/item on a molecular level rather than being transferred just on top, which results in a permanent solution under normal conditions. Since the dye can be re-activated at really high heat at any point, it is important to transfer a full design from a single sheet of paper in a one-step process. The ink can be reactivated at temperatures as low as 340F, and sometimes even lower, and could stain equipment or already pressed items.

Because sublimation is an additive color process, and it only DYES the color of the item, it is compatible only with white or very light substrates, as the color of a non-white shirt will bleed into the image (and black will block an image out entirely, so sublimation onto black t-shirts is not possible at all). It is also best compatible with 100% polyester garments and polyester-coated items . Other blends of polyester will work as well, but only the polyester content will be dyed – ie: 50/50 blends of poly/cotton will turn out half as bright as a 100% polyester garment. This method does not work on natural fibers (cotton, rayon, wool, etc) as it will wash out completely.  It will not transfer on non-coated items.

 

 

PROS: CONS:
  • Permanent transfers that last as long as the garment/item
  • Easy and fast set up and transfer process
  • Transfers realistic full-color photographs and designs with high detail
  • No texture of its own, easy to transfer on variety of coated items such as mugs coasters, mouse pads, ornaments and more
  •  High cost on inks
  • only compatible with 100% polyester or sublimation coated items that are white/light
  • Requires some design software/printer set up for proper color control

To learn more about sublimation, visit our Sublimation Basics page!

Note: We only sell and support patented, high quality inks made by Sawgrass.

 

 


 

Solvent Ink

Solvent ink is a more aggressive type of ink, available specifically for standing professional style printers with an inkjet style printhead, and is typically used mostly for outdoor applications due to its ability to adhere to a wide variety of media and vinyls and incredible durability. It is great for sign/banner vinyls, T-shirt vinyls and wallpaper media among others. The pigment is dissolved in a solvent chemical instead of water, which evaporates once it has been printed. Its chemical makeup makes it waterproof, fade-proof and scratch resistant in most weather conditions and lasts as long as the material it is printed on. However, due to its caustic nature, it is only compatible with special solvent inkjet printers, such as our wide format Mutoh printers.

Solvent ink is technically available in two different styles, though both are incredibly similar to one another (similar to pigment vs. dye-based ink differences):

Traditional  solvent– This ink has a stronger chemical makeup which allows it to dry faster and penetrate deeper into a wider variety of media that doesn’t necessarily need to be coated.  However, since the solvent chemical evaporates once it has been printed, it can cause hazardous fumes that can be inhaled by humans. Proper ventilation and space are required for this type of ink.

Eco solvent– “Eco” refers to the lower hazard level this ink is for humans.  Eco-solvent inks use a solvent that is not as aggressive, Hulk_findthesnail1usually derived from mineral oil,  and is better suited for indoor environments that don’t have a special air ventilation in place. The trade off however is slower drying times, with anywhere from a few seconds up to 12 hours of drying time depending on the media. This is becoming less of an issue with certain vinyls being added to the market, such as our ColorPrint Easy vinyl for garments which dries instantly.

 

< – – – Our beloved Hulk printed on Photo Tex Removable Wall Media for solvent printing

Traditional Solvent Ink Eco-Solvent Ink
PROS:
  • Faster drying times
  • Waterproof, scratch-resistant and fade-proof
  • Harsher chemical allows for printing on wider variety of media such as uncoated vinyl/banner material
  • Low costs for inks
  • Waterproof, scratch-resistant and fade-proof
  • No odor and made with biodegradable chemicals that are not as hazardous
  • Can be used in smaller indoor spaces
  • Low cost inks
CONS:
  • Hazardous fumes require proper ventilation and large working space
  • Requires proper disposal and handling
  • Slower drying times
  •  Not compatible with as many vinyls/materials

 

 


 

Direct to Garment ink

Direct to garment (DTG) is a process in which ink is applied directly onto 100% cotton fabric through a flat bed printer, such as our Epson SureColor F2000.  These inks are water-based and similar to pigment-based aqueous inks, and come in the standard yellow, magenta, cyan, black, and white colors. Once printed, they are permanently cured onto the fabric by applying heat and heavier pressure, ideally with a heat press around 335-340F for 1 minute or less depending on the color fabric. They feel similar to a screen print (some can’t tell the difference) and often times even softer because the process eliminates the use of vinyl or paper media, leaving ink to be the only thing on the shirt which lasts as long as the garment and is waterproof and fade-resistant.

DTGWhite or very light colored fabrics don’t need any prior treatment and the design is printed directly onto them, however since the ink absorbs into the fabric, it would be difficult to stand out on dark fabrics, which is why the printer has to print a solid base of white first on most brightly colored and black garments. That creates a heavier print with the additional layer of white ink added into the mix (titanium oxide is its main makeup which already makes it heavier), which can cause the ink to bleed through the fabric. To prevent this from happening, dark/black garments are coated with a pre-treatmeant solution by hand or using a machine (we use our Zoom AE All-Electric pre-treatment machine). The transparent pre-treat coating also helps the white ink to adhere better to the fabric. The extra pre-treat solution on the shirt dissolves in the wash, leaving the shirt with a clean and bright print.

DTG inks are most compatible with 100% cotton only or in some instances, cotton/poly blends. 100% polyester is not recommended because it is a plastic material which will not absorb the ink, causing it to sit on top of the garment. With average amount of washing, the print will fade dramatically over time. DTG may be used for cotton based, polyester-coated items such as mouse pads and flip flops, for display purposes.

 

PROS: CONS:
  • Waterproof, fade proof and scratch resistant
  • Highest quality print for garments on the market
  • Very soft and durable (should last the life of the garment)
  • Great vibrancy and detail
  • Printer requires monthly maintenance and upkeep
  • RIP software required, with specific settings that need to be calibrated every time a fabric is changed to a different fabric weave and thickness
  • Black or brightly colored fabrics require pre-treatment which makes for a longer process and potential higher costs for pre-treat solution and machine
  • Compatible with 100% cotton fabric only and some cotton/poly blends

 

 


 

Technology is constantly growing and improving, and there may be other types of inks for printing methods that weren’t included in this blog. This list is compiled to represent inks that we offer to our customers on a regular basis and are capable of providing great support over phone, e-mail or chat!

Desktop Solvent Printing 101: The Mutoh VJ628 24″ Solvent Printer

ValueJet-628What is solvent printing?

Solvent printing is more relevant in your everyday lives than most of you may think. Banners, stickers and decals are just a few of the very common products printed with a solvent printer. The pickup truck with the bald eagle and American flag on the back window – created with solvent printing. The sticker in your car that says when you need to get your oil changed next? Also, made with solvent printing.

 

Solvent printers traditionally range in size between 30” to over 100” wide and start at about $15,000. After you print on your roll of media, you will need a vinyl cutter to contour cut the finished product from the main roll of media. There are even printers available that have that have a built-in cutter, but it also has its disadvantages, which I’ll discuss later on.

 

Introduction of Roland BN-20 and Mutoh ValueJet 628

A few years ago, it was discovered you could print onto heat transfer vinyl with a solvent printer and transfer it to garments. This was a game-changer for apparel decorators who needed a solution for short run orders. No more turning down an order for two shirts and more money in your pocket. However, there was one problem that these apparel decorators were running into – the initial investment of a solvent printer and vinyl cutter was upwards of $20,000. That didn’t make financial sense for somebody who will only be using the equipment for short-run apparel decoration, not to mention the large amount of space a 54” printer takes up in a workshop when only 20″ of that printer was actually needed.

 

So in 2011, Roland introduced the BN-20 all-in-one printer/cutter. It was the first desktop solvent printer and it was perfect for users who wanted to create smaller products like garments and stickers. Media manufacturers began offering all of their medias in 20” widths for the BN-20 users to use. Over the last few years, people began to get frustrated with the speed of this printer as well as the price point, which was $10,000+. Mutoh took note and, in the summer of 2014, released the ValueJet 628. The VJ628 24” solvent printer rivals the Roland BN-20 in every way. The print speed is about 10 times as fast as the BN-20 and the quality matches that of a standard size Mutoh solvent printer. At first you may not like the fact that you have to have a separate vinyl cutter, but watch the video below, and you will see why I stand behind this product so much. Most of you probably already have a vinyl cutter and if you do not, we’ve put together a package with this printer and a 24” Graphtec cutter and it is STILL priced lower than a Roland BN-20.

What medias to use and markets to sell them

Now that you know what solvent printing is and have a brief understanding of the Mutoh 628, I am going to tell you what media to use with it and what markets to sell it in. Garment decoration is one of the main uses for the smaller solvent printers. Coastal has a wide variety of printable heat transfer vinyl and we even offer a comparison chart to help you determine which is best for your needs. These materials are great for short-run jobs and have a major advantage over heat transfer paper due to the soft hand and durability, which is comparable to a screen print. There is no need to have a 54” solvent printer if you are only printing stickers, unless of course your sticker is 54” wide, didn’t think so. We have a couple blogrecommended sticker/decal media available in the 24” width.

 

ROI

The most important part of this whole process is making money. There is no reason to purchase any of this equipment if you can’t get a good return on your investment. The Mutoh 628 is a very profitable piece of equipment and there are numbers to back it up. The average media for a solvent printer is about $0.30 per square foot and the average ink cost per square foot is about $0.20 Bringing the cost of consumables to about $0.50 per square foot. A standard sticker is about 4”x4” and costs about $0.055 in consumables. 50 custom 4”x4” stickers on stickermule.com sells for $69.00 or $1.38 each. That is over a 95% profit margin!! Even the printable heat transfer vinyl has a great margin. The Coastal Solvent vinyl is about $1.25 per square foot and the ink is the same at $0.20 per square foot. So your cost of consumables for garment is about $1.45 per square foot, which is about the average size of a printed graphic for a garment. If you are purchasing your blank shirts in a decent bulk quantity you are not paying more than $3.00 per shirt. For a short run t-shirt shop (1-10) shirts, a customer can expect to pay at least $15 per shirt. Bringing your profit on each shirt to over $10! Again, that is a margin of about 60-70%, which is great in this industry!!

 

Tips and tricks

One of the biggest aspects to any printing is color. It is very important to make sure you are meeting your customers’ expectations when printing color. The Mutoh 628 has a RIP software that communicates between your printer and your graphic design software.   It is basically telling the printer to lay down this much ink of this color to make the image appear on the print as it does on screen. Each media will take a different amount of ink to achieve the same color. So it is important to make sure you select the correct color profile for the media you are printing to.

 

Have more questions? Call (800) 562-7760 and ask for Alex!

Wall Art Made Easy

Use Photo Tex to create a beach scene indoors!

Are your walls looking a little bare? Do you wish you could find the perfect material for a home decoration project you or your customer had in mind? Coastal has a variety of solutions for cost-effective, beautiful wall décor that you can easily create for yourself or for a profit.

If you’re looking for easy-to-apply (and remove!) material that can be printed using a regular inkjet printer, try out our Folex TackJet material. Continue reading “Wall Art Made Easy”