PressWe measure
what others
eyeball.
Every print order runs through a 47-point production audit before a single squeegee stroke. Below: the live metrics from a 300-piece job approved this week.
Mesh Count Match
160 mesh for soft-hand discharge on 100% cotton
Ink Opacity Rating
Full-block white underbase on charcoal substrate
Color Separation Accuracy
4-color separation, Delta-E < 2.0 on all channels
Substrate Compatibility
50/50 poly-cotton — adjusted cure window +8°F
Cure Temp Verification
Plastisol cure verified at 320°F belt speed 4.2
47
Checkpoints
0
Reprints
6 days
Turnaround
47-Point Production Audit
The walkthrough
Seven stages. Every one audited. This is how a print job goes from artwork file to shipped box without a single reprint conversation.
Stage 01 · Checklist
Artwork Preparation
Vector artwork confirmed or rebuilt
AI, EPS, or PDF with outlined fonts
Color count verified against quote
Spot colors ≠ process colors
Halftone frequency matched to mesh
45 lpi on 160 mesh
Trap values set (0.25pt standard)
Prevents gaps between adjacent colors
Pantone references logged
PMS 286 C → Wilflex Ocean Blue
Client proof approved in writing
PDF soft-proof + physical strike-off
Rasterized artwork = pixelated edges, color bleed, and a reprint conversation nobody wants.
Why it matters
Artwork Preparation
Vector-clean, separation-ready
Cheap shops take your JPG and wing it. We require vector art or rebuild it at cost. Every color gets a separate channel. Halftone angles are set per ink type to prevent moiré. Trap values are dialed to your mesh count.
Proof turnaround
< 4 hrs
Why it matters
Screen Exposure
Emulsion thickness dialed per mesh
Underexposed screens ghost. Overexposed screens lose fine detail. We use a Stouffer 21-step exposure calculator on every emulsion batch. EOM (emulsion-over-mesh) ratio is measured with a wet-film gauge before coating.
Exposure accuracy
±2 Stouffer steps
Stage 02 · Checklist
Screen Exposure
Mesh degreased and dried
Ghost removal with Franmar Mesh Prep
Emulsion coat weight logged
1+1 coat, 18–22 micron EOM target
Exposure unit calibrated
Stouffer 21-step strip, step 7 solid
Washout pressure controlled
40 PSI max — prevents undercutting
Pin registration punched
Misregistration < 0.5mm tolerance
Tension measured post-coat
≥ 25 N/cm on all print screens
Lazy exposure = sawtooth edges on fine text, pinholes in solids, and screens that break mid-run.
Stage 03 · Checklist
Ink Mixing
Pantone formula pulled from guide
PMS Solid Coated, not memory-matched
Viscosity measured (Zahn cup)
20–25 sec for standard plastisol
Ink weight logged per squeegee pass
Target: 0.8–1.2 g/cm² deposit
Flash temperature set
230–250°F gel, not full cure
Discharge activator % measured
3–5% ZnF₂ by weight, mixed fresh
Strike-off printed and approved
Color match within Delta-E < 2.0
Eyeballed ink mixing = color drift across 500 pieces, with shirts 10 and shirt 490 looking like different jobs.
Why it matters
Ink Mixing
Pantone-matched, viscosity-checked
We mix to Pantone formula guides, not memory. Viscosity is measured with a Zahn cup before every run. Flash-cure dwell time is adjusted per ink deposit weight. Specialty inks (metallic, puff, discharge) get their own cure protocol.
Delta-E tolerance
< 2.0
Download the Print-Ready Checklist
The same 47-point audit we run on every job. Share it with your current printer and watch them either step up or make excuses. One email. No pitch sequence.
No account required · No sales call scheduled · PDF download, direct
Why it matters
Press Setup
Off-contact, pressure, squeegee durometer
Three variables wreck more prints than any other: wrong off-contact, wrong squeegee durometer, wrong print angle. We set all three with gauges, not feel. Pallets are leveled. Registration is locked before the run sheet is signed.
Setup time logged
22 min avg
Stage 04 · Checklist
Press Setup
Off-contact set (3/16" standard)
Measured with feeler gauge
Squeegee durometer confirmed
70A standard, 80A for fine detail
Flood/print pressure logged
Peel-back test on each color station
Pallet level verified
Machinist level across all stations
Registration locked and initialed
Print operator sign-off required
Test print on production substrate
Not a proxy — exact garment used
Wrong durometer on a fine-line design = ink smear. Wrong off-contact = ghosting on every impression.
Stage 05 · Checklist
Print Run
First-off approved by lead printer
Matches approved strike-off
QC pull every 50 impressions
Color density + registration check
Ink replenishment logged
No dry screens — flood coat before add
Tension re-check at 250 pcs
Screen fatigue affects registration
Reject tally maintained
Misprints tracked, not hidden
Run sheet updated real-time
Timestamp, operator, ink lot #
QC every 500 means you discover drift at piece 499. By then, you own 450 reprints.
Why it matters
Print Run
800 impressions/hr, QC every 50
We pull a QC check every 50 pieces — not every 500. Screen tension is re-checked at the 250-piece mark. Ink viscosity is re-measured if ambient temperature changes more than 5°F. The run sheet travels with the job.
QC interval
Every 50 pcs
Why it matters
Curing
Donut probe verified, no cold spots
Ink that isn't fully cured washes out. We use a donut probe thermometer on every dryer run — not an infrared gun, which reads surface, not core temperature. Belt speed is set per garment weight, not per shift preference.
Cure verification
Donut probe every run
Stage 06 · Checklist
Curing
Dryer belt speed set by substrate
4.2 ft/min for 6oz cotton
Donut probe reading logged
Core temp ≥ 320°F for plastisol
Wash test on sample pieces
5-wash test before bulk cure
Polyester sublimation check
Low-bleed ink on poly > 50%
Cool-down before folding
Minimum 90 sec post-dryer
Stretch test on cured print
No cracking = full cure confirmed
Surface-cured ink passes a touch test and fails the first wash. Donut probe is non-negotiable.
Stage 07 · Checklist
Final Inspection
100% visual scan under light table
Pinholes, scumming, holidays
Registration check on each piece
Overlay marks visible on edge
Color density spot-check
Densitometer on 10% of run
Reject documentation
Reason code + photo for records
Count verified against PO
Overrun policy: +2%, never short
Client notification sent
Photo proof of completed run
Shops that skip final inspection ship your client's event shirts with pinholes in the logo. We don't.
Why it matters
Final Inspection
100% visual scan before fold
Every piece goes through a light-table inspection before it hits the fold table. We're looking for pinholes, scumming, color inconsistency, and registration drift. Rejects are pulled, documented, and replaced from the approved overrun.
Defect rate (YTD)
0.4%
Ungated Resource
Ink type comparison
The three ink systems we run, side by side. No sales spin — each one is the right call for a specific job type.
Plastisol — Performance Matrix
Score / 5Opacity
Full-block coverage on dark garments
Soft Hand
Sits on top of fabric
Color Vibrancy
PMS-matchable with base
Cure Complexity
320°F — forgiving window
Eco Profile
Contains phthalates
Stretch Resistance
Cracks on heavy flex
Quick Specs
Best For
Avoid For
Not sure which ink type fits your job? Describe your substrate, color count, and quantity — we'll spec it in under 2 hours.
Get Ink Recommendation“I've ordered from three other shops. The first two delivered color drift by piece 200. Press sent me a photo of the completed run before shipping — every print matched the strike-off. We reordered 600 pieces two weeks later.”
Danielle Okafor
Marketing Coordinator · Meridian Health Systems
Press speed
YTD 2026
Per job audit
Standard orders
Start your audit
Ready to brief a printer
who measures everything?
Tell us your quantity, substrate, and color count. We'll send back a spec sheet and price within 2 business hours.
No minimum for quotes · 2-hr response M–F · First strike-off included