Curing solutions for Direct-To-Garment tshirts

The direct-to-garment (DTG) industry is a fast growing segment of the t-shirt decorating businesses.  It has potential to for great customer service and satisfaction due to the rapid turn around of finished goods and the limitless design possibilities.  However, it has some downsides in terms of profits.

We have written in previous blogs that the only way to make high profits in t-shirt decorating is to move product in and out of the production facility as quick as possible.  Labor costs are the real costs of t-shirt printing.  Whether you are talking traditional screen print or DTG.  Keeping your time down is how to keep your profits up.

What is the biggest time consumer in DTG production?  Curing.  Especially curing dark garments.  Let's talk about that production and a new way to resolve the bottle neck.

Typical production of DTG shirts
There are standard steps necessary to produce prints on dark colored garments.

1. spray the shirt with pre-treat solution
2. using a paper barrier, press the shirt in a transfer press to seal the fibers and dry the pre-treat
3. print the shirt
4. use a transfer machine (set to not touch) to cure the ink

What are we trying to accomplish?

The first press with the transfer machine lays down the fibers of the shirt so that the ink prints onto a flat surface.  This is necessary to get a clean print.  The second press is our curing system.  This can be accomplished in other ways that are faster and more efficient for both the operator and shop power consumption.  The traditional heat press ranges from 45-90 seconds pr/shirt for a full cure which is roughly 60 shirts per/hr.  With DTG machines capable of producing up to 400 per hour, an operator would need to utilize around 7 heat presses.  A single operator will not be able to keep up at that pace, and the power consumption of is crazy. 

What is the solution?  

A conveyor curing system that heats the water and has convection air to move the water vapor out of the chamber.  DragonAir Core Technology.  Ok, nice sales tag.  But seriously, this is the answer to increasing production and getting a consistent final product.  If you can pull the shirt from the printer and place it on a conveyor, then you open the transfer press for other uses and the operator has one less task.  Also, in a conveyor system, you can load from multiple DTG printers so that you would reduce the power required for the transfer presses.

So how and why does this work?

DragonAir Core Recirculation Technology

Think of convection ovens.  The idea is to move heated air around the product and to exhaust the water vapor out of the system.  The DragonAir does just that.  By utilizing filtered air and digital temperature control this unit effectively and consistently cures DTG garments.  

The final garment has a more vibrant look and it feels better.  The cure is consistent from shirt to shirt and the cost of production has dropped.  And isn't that what we are going for?  Production cost of goods to decrease, production to increase, and a great looking product.  

For more information, check out our BrownDigital web site at www.brownmfgdigital.com.

Show season kicks off!

new for 2013

This past week, Brown Manufacturing Group has launched the 2013 trade show season with two great events.  The PPAI show was held in Las Vegas and we were proud to be members of the decorating pavilion. The Imprinted Sportswear Show is closing today in Long Beach and we have shown at this event since it began decades ago.

What makes these so special?
The PPAI show gives us a different side of our customer base than the other events that we exhibit at.  We get to see large decorators and manufacturers of unique items sold in the promotion world.  Many of our athletic jersey customers also exhibit at this show and visit our booth to see what's new.  Also, we get to solve unique problems that come up in this side of the printing world.  That kind is customer service is just fun.

The ISS show is big and bustling with garment decorators, our prime market.  This year the atmosphere and attitude of the customers attending has been more upbeat than the past few years.  We think that is a sign of an economy on the upswing.  California has suffered from this recession and this show has been a representation of that.  However, good things are coming.

What good things are coming?
Brown uses the ISS Long Beach event to introduce new products and ideas.  The customer base is receptive and it is a great way to start a new year.

New at is show is the TRX Series conveyor oven.  This includes the TRXi software that is amazing.  With this software, operators have complete control of the parameters of the dryer using a touch screen display. Cool, but what is really amazing is that these parameters can be saved for future reuse.  Up to 36 different jobs can be stored.  This software can also analyze the cost to run the job and the lifetime running cost of the machine.  There are more features to list, so check out the web site.

Also new at this event is Brown Manufacturing Group's new product division, BrownDigital.  This division displayed the new DragonAir line of curing units for direct-to-garment printers,  I know, about time someone made these!  These units offer air flow and convection heat through DragonAir Core Technology.  Go to the web site and check it out.

Another new product is the LazerLoad feature for the NumberPrinter line of athletic numbering machines.  This feature gives the press operator adjustable laser alignment lights to mark single digit and teen digit shirt placement.  A time saver for any athletic numbering shop.




Innovation is the key.
These hard economic time have been a struggle for many of our customers and competitors.  We have dealt with this in our usual style, by developing the products that solve problems and supply necessary tools.  By advancing our product line forward we have sustained our customer interest and grown during these past years.  Development of innovative and creative tools has been the benchmark of Brown's success.

Please take a moment and check out the new items.  We think you will be curious on how these can help you.

TRX Series Conveyor Oven Introduction

Brown Manufacturing Group, Inc. introduces a new series of conveyor curing systems.  The TRX Series ovens offer the reliability and durability you expect from Brown brand dryers and the highest level of control package ever offered on an oven in the screen printing industry.  For the print shops who drive a high level of production and are attempting to get control of the shop rate and costs, this is a tool to have.

So what, exactly, does this thing do that is new and different?

While the TRX offers the same temperature accuracy of our Sierra and
UltraSierra2 lines of machines, this line also has the ability to program dryer settings and store them for future use.  Up to 36 different programs can be stored using a touch sensitive screen.  This means that when an operator changes garment types, he selects a predetermined set of parameters by pushing a button.  No more guessing what temperature and belt speed to run.

A few more features include:

• Scheduled maintenance programs with alarms.
• Industrial stack light with alarm notification.
• Onboard diagnostics with alarm.
• Eco Mode for low power usage during operator down time.
• Auto shut-down mode.
• Cost analysis per job and per piece.
• Cost analysis for the life of the machine.
• Time/Temperature/cost range analysis per job.
• Password protection.
• Overhead display of current temperature.
• So much more....

So why the excitement?

Every shop has to keep track of production settings for the different type of garments.  In small shops, this information is usually in the operators head.  Not a good idea.  In larger shops, this is documented and the operator has to look up the settings and manually change the dryer to match.  With the TRX, just enter the parameters in one time and save them.  When the operator needs that again, touch a button.

Additionally, for production managers, the overhead display is visible from anywhere on the production floor.  The Stack Light gives visible alarms that can be viewed from anywhere on the production floor.  The running screen reads what program is activated and its preset requirements.  Wow, a lot of really useful tools.

On top of all that.... it tells you when it is broken, what needs to be maintained and how much it and your jobs are costing you.  Man, I wish all my shop tools could be that specific.

For more information.

This dryer is on our web site www.brownmfg.net and, it is so cool, it gets to have its own.  www.trx-touch-screen-conveyor-dryer.com

Unleash this monster in your shop, today.

Show specials. Are they really special?

So, did this pricing catch your attention?

That is one of the ponderings that exhibitor sales people and trade show directors discuss.  The Show companies want the exhibitors to provide special pricing at their event.  This gives everyone something to talk about and provides a reason for an attendee to make the trip.  

We have tried many different specials over our 30 years of trade show experience.  We have offered free freight, extra add-ons at no charge, deep discounts and free on-sight training.  (ok, maybe that last one wasn't a good sell.  Who wants us in their building?)  

This latest round of specials has gotten some attention.  Partly because the world is getting better at e-business and this has been viewed by many people who are on our e-mail list.

This is the question for our readers and customers.  Does a show special excite you enough to get you to attend an event?  If it does not, then what would?  

The argument is that there are too many conventions.  However, we meet new people at these events every time.  We get to introduce existing customers to new products each time we see them.  If this happens each time, then how can there be too many.

Ok, so now I am ranting.  

Take a look at the special and tell us what you think.  Or better yet, visit us at a show near you.  We are at them all.

Custom built machinery

Custom built machinery.

Did you know that Brown Manufacturing Group makes custom equipment? For over 30 years we have designed and built machinery for some very interesting processes.  

This unit, still in its final assembly, is for a customer with very tight space requirements.  They are in a very narrow shop and need a dryer to accommodate high production.  


We have also designed machines for curing skis, nail polish bottles, mirrors, casino gaming machines and auto glass.  Our printers have been modified to print everything from umbrellas to folding chairs.  


These projects put a bit of spice into the engineering department.


Do you have any printing projects that need a better solution?  Call us and lets see how Brown can help.

New Years News

January is a new year.  For Brown Manufacturing Group that means a new show season.  We have already visited Las Vegas at the PPAI show and we appreciate all who spent time with us there.  This week we head to ISS Long Beach.   http://www.issshows.com/long-beach/ is one of our favorite events.  


We look forward to breakfast at the Long Beach Cafe.  http://www.thelongbeachcafe.com/.  It is the best breakfast on the show circuit!


Our first discussion for a major show is what design are we going to print.  This time, our in-house print Guru, Mike Green is printing a great design donated by Great Dane Graphics.  Check this out!

Then comes the question of "how much stuff can we get into the booth". This is where our personal diet plans come into the conversation.  Trust me, if losing a few pounds could get another machine into the booth, Mike would certainly give it a go.  However, if you have met him, it has not be an achievable goal.

This show we have the ElectraPrint 68 with a 240V drive system and the latest upgrade on the Set-n-Go pre-registration system.  We will also be showing the ElectraPrint Junior machine and a full line of manual equipment.

The show special for this weekend is a hot one... check this out.

Please take a moment this weekend and visit us in booth #153, our usual office and check out the latest offerings.  As the phrase goes... see what Brown can do for you.

House cleaning

During the slower months many of our customers take the opportunity to clean up their shops.  Just a note, this should be more of a weekly or daily event and not just during slow times.  During this clean up time there are some tasks that should happen and some inventory assessments that are recommended.


Machinery maintenance
After the windows, floors, bathrooms and showroom are polished it is time to work on the machines that earn you money.  If they are not in excellent working order, then you are not going to make the money you should in the future months.  


Let's start with your dryer.  Large or small, a screen print shop's production is all dependent on the functioning of the dryer.  So your first task is to clean your dryer.  You should check all of these items:

1. Heating elements.  If you have quartz elements, make sure they are clean.  If you have cal-rod or brick type then just confirm that they are all functioning.
2. Fans.  Exhaust fans, intake fans, cooling fans.  Are they clean and functioning?
3. Filter systems.  When is the last time you really checked and cleaned those?  Now be honest.
4. Drive system.  The motor, chain and gears should be clean of lint and re-secured.  
5. Control panel.  Yes, you have to clean those.  Get your shop vac out and suck up all that lint that is in the panel.
6. Gas train.  Are all your fittings secure?

Now we can move onto your printers.  These are what you have your hands on every day.  If you have used a hammer or a pair of pliers on any of your presses within the last month, then you have serious work to do.

1. Re-level the press.  This does not mean using a carpenter's level.  Confirm with your machine manufacturer's instructions on leveling your press.  This will take some time but it is well worth the effort.  It will pay off in future set-ups.
2. Replace and repair all parts.  No more burnt platens.  No more bungee cords, no more pliers for knobs.  Having a press that functions well will speed up production and earn you more money.

Spin 360° around your shop.  See all those other pieces of machinery that you need?  Fix and clean them.  Do not procrastinate because you will be ticked off during your next print run that you did not fix the problem when you had time.

Parts inventory.

Large production houses determine which parts they should own for all the machinery in their shop.  They do this at the time of purchase and often have stock on their shelves.  This means minimal down time in the future.  Now, they have larger budgets than most but there are some "rules" that can help you decide what you should have.

1. Is there a part on any machine that is difficult to get or has a long lead time?  If so, stock one.
2. Are there parts on the machine that if broken, will shut down your operation?  If so, stock one.  One that comes to mind is a motor and motor control for any dryer that is over 3 years old.  This is service experience talking.  I can bypass most parts in a conveyor oven, but not a DC drive motor.
3. If you run an automatic, what are the essentials.  What air parts are essential?  Any boards that you should have?
4. Screen processing equipment.  If you do not have a bulb for your exposure unit on your shelf, you should be ashamed.  It is not as if you can get them from Home Depot and you are not really going to use the sun in a case of desperation.

Spin 360° around your shop.  See all those other pieces of machinery that you need?  Consider what parts are essential and buy them.

The cost.

Really, there isn't any.  Yes, there is some initial out of pocket expense.  But what is the cost of down time.  Way more than this little bit of time and inventory.

Enjoy your cleaning.  It is a quiet time of reflection of the great work you have done and preparing for future growth.