DTF Production Systems

The garment decorating industry is at an accelerated pace for new technology and revitalization thru modification of old technology.  DTG launched the POD landscape that is now offered thru all levels of the supply chain.  Behemoth producers like Amazon and small community printers are adding POD tools to their production facilities to meet the consumer demand.  

The presentation of DTF into the production floor is not new, as all facilities have used transfers for decades.  However with the updated digital printing of these transfers this process has shifted many facilities to needing high volume DTF systems to fulfill orders.  

Brown Manufacturing offers 3 options for high speed DTF that will increase the speed of bulk orders with minimal labor costs. 

Level 1

The MasterPress is a base unit that features 2 heat presses and 5 shirt stations.  This allows 2 operators to load, press and peel in a small footprint.  Featuring a simple control panel and independent, adjustable temperature and pressure for the heat presses, this is a lower cost alternative for speed for the bulk DTF production.

Simple 120V power supply and a small air compressor is all this unit requires to quickly become operation in any shop.  Just map out spot on your floor and plug it in.

Level 2

If labor reduction is part of your production requirement, then the need for speed and accessories will move your shop to the next level.  Flexibility in design and additional options will amp up the production and reduce the operation to one person.

This heavy duty press comes with one heat press but has an option for two.  It also has these options:

• Automatic feed system
• Automatic peel system
• DTG pretreat sprayer system

With one press, an auto feeder and an auto peel, the operator is only loading shirts.  With a larger unit, add a 2nd operator and the speed increases with one shirt load person and one shirt unload.  

Level 3

Design your own system for exactly the flexibility your shop needs.  This level allow the system to both DTF and screen print.  Add print heads, loaders, peeler, multiple heat presses, flash units and DTG pretreat sprayers all on the same system.  No matter the job needed, one machine will have the tools.

Which one is right for your production needs?  Contact our Brown sales team to plan out your improved production facility or call 616-249-0200 for immediate information.

Thank you

 

To our customers, partners and staff,

For Brown and BrownDigital, 2024 has been full of growth and exciting opportunities. We want to express our deepest gratitude to our amazing staff – your commitment and perseverance have been inspiring. And to our wonderful customers – thank you for your continued support and belief in us and our products. 

The launch of the new BP Series Electraprint was met with enthusiasm from our existing customers and we have added plenty of newcomers to the family as news of this product has spread.  The Brown team looks forward to additional conversations on this 12 Station machine as well as all of the product line.

The partnership with Brother International on the Digital Line DTG production machine has been tremendous.  The challenges of the short learning curve as well as the interaction with new clients has energized the full sales team and driven our design team to think creatively about future possibilities.  This is a joint project that requires the concentration of Brother USA, Brother Japan and BrownDigital to grow it to its fullest capacity.  2025 will be just as exciting.

The expansion of the Brother Digital Line and the general industry-wide growth of digital printing has pushed the BrownDigital Linx team to continually add features to both the web-based and desktop versions of Linx Integrated Product software.  If you have not looked into this barcode driven production tool, we highly recommend you consider it.

All of the items listed above are developed, built, shipped and serviced by our highly capable Brown team.  Whether your business is adding new, expanding for new features, or fixing what is in your shop, the Brown staff has exemplified quality and dedication throughout the process.  Our team does work as a team and these amazing products exist because of them.

So from all of us at Brown to all of you, our customers and partners, we wish you a happy holiday season and look forward to 2025 and all the events yet to come.

Essential tools for POD profitability

Print on Demand is changing the industry

With the rapidly growing demand for individualized prints, social media driven trendy garments and next day delivery, the nimbleness of every garment decorator is being tested.  The advancement of DTG and DTF production technology has improved the response time for web driven orders.  New machinery like the Brother International Digital Line which integrates POD and reduces labor, are becoming more and more essential. A vital issue to stay profitable in this fast changing environment is internal work flow management.  Paper orders on the shop floor have got to go.

DL-2400 Digital Line

BrownDigital Linx Production Software Suite

In a previous blog Linx, we explained how Linx pulls orders directly from web stores and feeds those orders to production machinery with automated tools.  The Linx Software suite has expanded to include cloud based inventory management, purchasing and product creation.  Additional features within this software packages add a depth of resources to the constant changes that occurring in this market space.

• Product Creator and Product fixer will merge all store products into one application for production an inventory management
• Build-to-Stock (BTS) pushes stock inventory builds, manages returns for FIFO control, and gives full control to the production manager to keep within seasonal cycles.
• Order Submission provides an access point for POS
• Cloud management of floor production
• Analytics of real-time floor production

Is this only for garment printing?

The answer to that is a firm NO.  POD is a market trend that applies to many products.  Garments are the highest volume however these issues apply to any one-off customized item.  Linx Software suite can connect to laser engravers, sublimation systems, embroidery stations, cutters and plotters and many other tools of the trade.  In addition to garments, the inventory management is open to any base product such as trophies, mugs, plaques, posters and many more.  

Linx Software suite connects to any open API platform.  This includes Etsy, Shopify, Shipstation, Amazon, and many more.  Contact BrownDigital today for additional information of how Linx Software suite can improve your work flow.

Thank you for an outstanding 2023

 2023 has been an amazing year of expansion and growth.  Brown and BrownDigital have expanded in personnel, product lines and facilities and we are already busting at the seams.

In the summer we added a Crown to our life.  A building on Crown anyway.  This doubled our production space and allowed for larger projects to expand.  Our staff was thrilled with having more room to work in and spaces they could call their own.  This building added 3 overhead loading doors, 4 docks and way too many offices.  

The Brown product line expanded into their space with the ability to put up many machines at the same time which allows for additional testing and product development.  Yes, there are some cool new features in the works.  It also allowed for the development of a larger ElectraPrint machine that should be introduced in 2024.  The other feature that has sparked the growth of our Brown business is custom colors.  Our local high school is all blue and orange.  Go Rockets!

BrownDigital software developed many additions to the Linx suite.  Inventory, product fixers, purchasing as well as new connections to other platforms.  The diversity of this product line gives solutions to most POD production issues and it applies to a diverse area of application.  That software team has been gettin' it done.

The BrownDigital machine team is amazing.  The flagship FireFly product line has bloomed to a myriad of applications.  From the initial design of individualized curing, this has transitioned into a workhorse for applications from screen print to pretreat to DTG to wide format.  The diversity of possibilities is very exciting.  The Digital Line product for Brother International has opened additional opportunities for the FireFly and all the components involved.  

What is so interesting about our new facility is that it has allowed for bigger items to spread their wings and for the Brown staff to take ownership of specific products and make that section of the building all their own.  Our software team developed an internal Linx IC that has allowed for easy communication and information sharing within all facilities and our partners.  We expect that software to broaden our reach for direct contact with our customer.

Thank you for your investment into Brown and BrownDigital in 2023.  All of these changes excite us to create new products, adjust existing ones and grow into new areas.  We are excited about 2024 and what that will bring.  

Cleanliness is the first maintenance task for every machine

Our service department often is asked what the maintenance requirements are for any and all of the machinery we manufacture.  We appreciate machine owner's desire to keep their investment in peak condition for maximum production and long life.  For some of our products, the maintenance list is quite low as are the suggested stocking parts.  However, as the complication of the machine increases so does the upkeep. 

Many long standing customers will brag that they have kept their machines in proper working condition for 20+ years.  While this is a testament to the design and durability of these machines it is also a good determinate of the condition of the shop.  Well maintained, but could use some updating. So, as we do appreciate the compliments and understand the owners pride of ownership, there is benefit from keeping updated tools in your shop.

Returning to the question of maintenance requirements, as machines increase in complexity the list of daily, weekly, monthly and bi-annual tasks gets longer.  These tasks will be noted in the manual that is provided with the equipment.  If the machine is equipped with computers, then maintenance tasks are available within the software and reminders for mechanical maintenance can be preset.  The use of this software feature is very helpful in managing all of the essential tasks.  Some customers use this software to schedule additional tasks within the production floor for non-computer driven devices.

The number one maintenance task for any production floor is cleanliness.  

Textile decoration as an industry is inherently dirty.  The lint from fabric floats through everything and the production processes typically require liquids that are sticky.  So lint and fibers will get stuck to everything.  The lint will also adhere to any greased or lubricated surface of a machine.  And it will get pulled into fans, fan belts and chain drive systems.  So let's see chat about havoc that can create.

• Electronics will overheat and malfunction due to clogged fans
• Electronic connections will degrade due to lint interference 
• Lubricated surfaces which allow for smooth machine movement will get clogged, affecting print quality and machine operation
• Conveyor belts will wear faster and will transfer dirt and debris onto the final product
• Registration and indexing systems will become inconsistent due to dirt and debris and this will affect registration
• And machinery aside, what employee wants to work in a dirty shop.  And employees are a production floors most expensive and important asset.

How clean do we suggest?  Lint free is the key.

How do you  keep a garment decorating shop lint free.  You do it by making cleanliness a top priority on the floor.  Cleanliness makes for happier employees and fewer shut downs which will increase production and profits.

The good, the bad and the ugly.

Let's start with the simplest items, fan filters.  These are designed for easy on/off.  And they are used to keep the electronic cabinet fans clear of debris so that they can move cool air across the electronic components.

Then we can move to the fans.  Whether in the control cabinets or used to move air in and out of a curing chamber, they are essential to the design and function of your equipment.

Now what does all this do to internal components?  Electronic components shut down when they are too hot.  Being covered with lint will cause this.  Relays will fail, switches will stop communicating and thermal cameras will shut down.  Production stops.

What about the chassis and the mechanical items.  They appear to be pushing through but are they?  Or are you setting them up to fail?  And there are no GOODs here.  Seriously, yuck.

And what employee wants to touch these?  And if they do, how do they touch fresh garments and ship them completely clean?  

Ok, we think we have made the issue clear.

So this week, at the end of a work day, pick something and clean it.  Start with wiping down the outside, both the controls and the chassis.  Then get a vacuum and clean out the internal controls.  The whole job should take 20 minutes.  Then another day, pick another machine.  Go through the whole shop and clean everything.

Next time we will chat about those preset maintenance items available in your software.

Innovation Center at Brother International

 

It has been a long time coming and the Brown staff is excited to see that their hard work has paid off.  Brother International opened a new training facility at their Bartlett, TN location and the BrownDigital product line took center stage.  

This new product line has been under wraps for 2 years.  A single operator loads a garment and these garments are pretreated and digitally printed and returned to the same operator.  One guy does it all.  Amazing.

Thank you to Brother International for the opportunity.

POD production? It's where the world is.

Our roller coaster world has made traditional printing businesses  take another look on how they generate orders.  When schools and restaurants were closed, many of our community printers had to consider other avenues for revenue generation.  The world of online shopping became essential for all decorators, whether one off orders or bulk.  These orders can be challenging to pull into standard community printing production management.  

The old school paper production tickets are messy and confusing for small orders.  Barcode systems that can function for both small and bulk orders are cleaner and more efficient than sheets of paper floating around a production floor.  Scanners at each workstation can pull up all order details within seconds and connect directly with shipping software.  With Linx Production software, the barcode will also drive the printers, laser engravers and sublimation systems.  

Wait, what?  It can connect my online to my production machine and back to my shipping software?

Yes, Linx Production software can do all that and with additional modules it can connect to QuickBooks® and manage inventory and purchasing and print bulk orders.  That is a lot of features that every shop needs in the world of POD.  

While much of the US is opened back up schools, businesses and events, the online store is now a required element to a business.  Many businesses who used to allow sales people in their doors are now preferring to look online and connect through teleconference platforms.  These options allow higher time flexibility for the buyer and keeps additional people out of their workspace.  With the latest variant wave, this is a required element.

So how does Linx Production software do all that?

Beginning at a web store, information for an order is pulled into Linx and a barcode is assigned. This information includes garment data as well as art and print locations. The PNG artwork is ripped for the DTG as well as scaled for garment size and print location. For other print mediums, the art is converted to match the requirements of the output device.  The operator loads the item, scans the code and the output device has all the information needed for production. Print specifications are preset by the user as well as pretreat and cure requirements.

Orders can be sorted by all major factors. This aids in purchasing, product picking, pretreat scheduling and customer management. At shipping, a binning system allows for gathering of multiple items of an order with notifications when an order is complete. In the QC department, if a product does not pass inspection, the barcode returns to th production schedule for a reprint.

A QuickBook plug in will also connect your orders directly to your billing department. Inventory modules are available for small and large users.  Custom API connections are available to give full flexibility to your production needs.

How do you  get started?

Call BrownDigital today for information on pricing and how this system can be used in  your shop.  It is quick to install, simple to learn and will speed up order processing for small or bulk orders.

So many decorating options.

Brown did some recent DTG print testing and I had some thoughts.  This particular test involved a print run of about 72 shirts ranging from youth medium to adult 3xl.  It has a white crest print and a multi-color full back on a dark shirt.  A typical order for a community printer.  And a profitable one if handled correctly for your shop.  

What is correctly?

DTG

This run was done with a digital printer and our Synergy pretreat and FireFly cure systems.  At 72 shirts with a white under-base, this job took almost 2 hours.  The image quality was fine but it did look like a digital print. They are clean but they do not pop.  The estimate on the cost of each garment includes time and materials.

Shirt $2

Ink $0.95

Pretreat $0.30

Shop time cost  $1.66

Labor $0.83

Total cost per shirt $5.74     

The positive to DTG  printing is that once the art is approved there is no additional processing of the art to print.  A quick conversation from the PNG and it is ready.  Also, employee training is minimal.  Everything is determined by the Linx program within the machines and the operator only loads and unloads.  Additionally, the software will resize the art to the size of the garment, the job is easily repeatable and there is no clean up at the end.

Screen Print on an automatic

So, what would happen if it were printed on an ElectraPrint auto press?  Front and back, this job would be finished in less than an hour.  The look would be crisp and it would pop off the shirt.  The size of the print on the youth would be the same size as on the 3XL, which is a negative.  There is set up and clean up.  The art needs to be separated and screens need to be made.  Presuming that this design could be printed with 6 colors, this is the estimated cost per garment.

Shirt $2

Ink $0.06

Films/screens $0.08

Shop time cost $0.83

Labor $0.42

Total cost per shirt $3.31

Screen Print on an manual

So, what would happen if it were printed on an MasterPrinter manual press?  Front and back, this job would be finished in about 2 hours.  The look would be crisp and it would pop off the shirt.  The size of the print on the youth would be the same size as on the 3XL, which is a negative.  There is set up and clean up.  The art needs to be separated and screens need to be made.  Presuming that this design could be printed with 6 colors, this is the estimated cost per garment.

Shirt $2

Ink $0.06

Films/screens $0.08

Shop time cost $1.66

Labor $0.83

Total cost per shirt $4.63 

Is cost the only factor in the production path?

Well, we can all say "no" to that answer.   But there is $2.50 per shirt here in profit.  So COGS cannot be ignored.

COGS is a significant factor.  That calculation has to include machine time, shop time and labor time.  However, judging the flow of your shop, the availability of your staff and their skill sets, and the print preferences of the final customer will sway the final production decision.   If they want "pop" then they will want screen print.  If they prefer a soft feel, then DTG is a good plan.

So the real answer is that there is not a "correct" way to do this except to follow some basic guidelines.

1. Is the customer happy with the finished product?
2. Did you deliver on time?
3. Did you make a profit margin that you would want repeat the job?
4. Did this job delay other jobs that were more profitable?

If your answers are yes, yes, yes and no, then you have chosen wisely within the parameters of your production facility.  If any other answer comes up, then reconsider for future jobs what needs to shift.  Was the print accepted, was job late, or did you not make enough of a profit margin?  Because in the end, it is a happy customer with a solid bottom line that we are all striving to achieve.

New web site launch

We are excited to announce the launch of new web sites.

brownmfg.net is our main catalog site for Brown equipment.  

This site features the products for screen printing, from screen room to final cure for all production levels.  Additional content will be added as it becomes available and this site is more mobile friendly than our previous site.

On this site you will still find the popular ElectraPrint automatic printers.  These are the only fully electric machines on the market.  There are suggested parts list for many of the machines as well as cut sheets for installation.

From this page you will find links to the associated products such as the Set-N-Go and the QuartzAir flash.  

Within this site you will also find information on all of our t-shirt ovens as well.  This includes the TRX series, the UltraCure x-series, the PonyDryer and the Sierra dryer.  It is a comprehensives site that will provide all the details to help choose the right one for your shop and to help plan for the installation.

brownmfgdigital.com is our main site for BrownDigital products.

This site features the products designed for DTG decorators.  Direct to Garment printing has different requirements for preprint and curing than screen print and these products will speed up the workflow for all levels of production.  

On this site you will find the DragonAir Crimson which is a small DTG dryer designed to cure DTG prints at a faster rate and higher quality than a heat press.  

Also on this site, is the Linx Control System integration software.  This app takes your web store orders and integrates them directly with your DTG printers and through to your shipping department.  This is all run on a barcode system that keeps production flowing smooth and creates consistency within your final products.  

We invite you to peruse these sites.  You will find something that will help you shop with its production flow, product quality, or bottom line.

Trade shows have restarted. Are you coming?

 Our first show of the 2021 season is fast approaching.  We are truly excited.  There are so many positives to the trade show experience that it is hard to list them all.  Most importantly is the direct connection we get with our customers.  We are on the phone all day, we have many emails, and we have taken full advantage of new tech with FaceTime and TeamViewer and Zoom.  But there is a different connection when the interaction is face to face.  Or mask to mask as these will be.  

It is also better for our customers.  It is harder to determine what is the right path when purchasing a capital good if you cannot touch the product.  Consumables are easier, but hard goods are similar to buying a car or a house.  The user needs to be in direct contact with the product to understand all of the benefits and how they will affect their personal production floor.  We find that very fitting with manual screen presses.  These are certainly a "feel" item.  The operator has to like how the press flows with their hands.

So now both the exhibitor and the attendee have new opportunities. Visit us in Irving and in Indianapolis.  We can't wait to see you.

Time to reconnect and restart

Are you ready?

Even in Michigan we are beginning to see the world shifting back.  It was with great celebration that our own John Ball Zoo opened to the public and that the local little league signed up for t-ball.  There is more work to do, but now is the time to connect with those customers who limited their ad dollars to survive the past year.  Restaurants, event venues and tourist businesses will be eager to see creative new marketing suggestions to restart in the post-COVID arena.

So what new do you have for them?

The same old-same old will feel comforting.  Yes, we could all use a little pre-vid ease.  However, since EVERYONE will be trying to get attention, what will you bring to the table that is new and interesting?  We have had plenty of time to think about that.

• Can you offer longer runs at better prices?  An ElectaPrint can help with that.
  
• Do you chase the athletic market the is back in full swing?  Screen printed number are less expensive and nicer for the athlete than heat seal.  But you need to be equipped for that.  There are lots of options.  Check out the Slider.
• Looking for short run customization? DTG is a great source for new work.  The DragonAir Crimson could be just what you need to cure those goods.
• Do you offer super fast turn around?  The a FastFlash would speed you up.  Is yours hot and ready?
• 
  
  Can you reduce your set-up fee because you are making screens quicker?  An LED exposure unit would give you this capability.

Go for the close.  Give them a reason to return.

People talk big, but it is the repeated on-time delivery of quality goods that keeps them coming back.  It is creative thinking of new ideas that generates new revenue.  It is the commitment to internal growth and change with complete follow through that grows businesses.  Doing the same work each day should create a smooth flow of production and a quality product.  However, if you do this for too long it will also cause stagnation.  The end of the pandemic offers each business an opportunity to add something new that will generate a buzz of excitement.

DragonAir Crimson engineered for DTG production

We are SO EXCITED.  The DragonAir Crimson oven is fresh out of design and through production and is into DTG print shops throughout the US as well as globally.  Our engineering team dug deep to get this done and the design is a winner.  It addresses all the technical requirements for curing DTG inks and incorporates them into a machine constructed for low volume, high quality production.

Though small on size, this machine is packed with features that are essential. Direct-to-garment printing uses pretreat solution and ink that requires high volume air flow and stabilized heat.  In a short chamber, the garment needs an additional boost to get the cure needed.  These parameters were used to engineer this machine from the ground up just to meet the needs of DTG low volume production.

Major control features

The Crimson comes equipped with many features that professional DTG printers know are needed.  Starting at the control systems, this unit includes digital temperature control on the main chamber.  This reads the temperature at belt height and regulates cal-rod style heaters for optimal control.  These heaters are also have indicator lights for quick and easy verification of function.

Additionally, the Crimson includes a heat bump on the front of the heat chamber.  These quartz heaters are controlled separately from the main chamber and are monitored with indicator lights.  This allows rapid response to garment temperature requirements and quick heat build of product for faster production.  

The air requirements of DTG inks are serviced by the variable air speed control.  DragonAir Core Technology circulates hot air around the heaters and onto the belt for rapid evacuation of water.  This air can be quickly adjusted to match a garment's specifications.  Also, the discharge from the garment can be funneled through the heavily insulated air box on the end of the chamber.  This is designed to connect to the exhaust system of a production shop and to contain the water vapor to exit from one location.

Construction features

The heat controls combine with a variable speed belt to give the operator a wide range of curing options.  This speed control is connected to a heavy-duty drive train designed with long lasting durability.  Crowned rollers making belt tracking simple and adjustable baffles are used to shield internal temperature from external influences.  All of this is packaged nicely on an industrial frame which requires minimal space.

The DragonAir Crimson is engineered specifically for DTG low volume production.  This small unit is the perfect  addition to any small digital facility who is ready to move on from using a transfer press for curing and is looking for a true DTG production machine.  

Wow, what a year. Big challenges with huge accomplishments.

 Seriously, murder hornets?

We are printing the annual shirt give away for our staff and we wanted to commemorate all that we have accomplished and we referenced all that has encumbered us.  2020 is a year full of challenges.  When the list was drawn up, it amazed people that there were so many challenges that they did not remember all of them.  And we had to remove some from the list because the list got too long. 

However, the important items on this list are the accomplishments.  These are made more impressive because it is 2020 but our staff has pulled off some simply amazing things.

The new marketplace economy, does it apply to all sectors?

 In our whirlwind of 2020, everyone is adapting.  On demand commerce is bigger than ever.  One-off garment demand has not slowed.  And now Amazon is in the mix with their latest addition.  

Amazon to Buy $400M in Kornit Digital Printing Equipment, Open New Merch by Amazon Facility

Our BrownDigital line of machinery is a solution for a production issue within DTG printing and Brown has benefited from the on-demand increase.  However, our smaller community printers have been highly impacted.  Their business is face-to-face and relies on local events, schools and tourism.  Thanks for the gradual reopening in some states we are seeing those customers printing again.   They have gotten a small boost from the mask mandates and this is a new product line for many of them.  Brown's new mask platen is a nice solution to making this a profitable product.

One of the largest issues that has affected industrial goods is how to show people what is available.  Trade shows have become virtual.  Online video presentations do a nice job.  But, like buying any large item, many people would prefer to personally see an item run.  As an example, in a recent car purchase there were 2 vehicles.  They were the same cars, only a sedan versus a hatchback.  They were similar mileage and the same age and the same price.  The hatchback would have been preferred and if we could only have purchased sight unseen it is what we would have chosen.  However, we were able to drive both and the sedan was a better choice.  So when selling large ticket items, most people would prefer to see what they are buying.

Brown and BrownDigital have spent time establishing customer connections so that there is confidence that what we manufacture is well designed and will be well supported.  However, we are looking forward to in-person sales events.  Contracts for these events are signed and we know that the hosts are spending time creating a safe environment for visitors.  But will they come?

The pondering of this whole conversation is how to move either back to in-person sales events or how to present large ticket items in a remote world.  As time passes and more time becomes available, Brown will be presenting more video information for both new items and repair tips.  Let us know what you would like to see.

 

 

Linx software is a solution for production management

Orders come in and orders go out.  In many shops that means that there are pieces of paper following that order through all through the production process.  Some shops place those in plastic protective sleeves to keep them from flying about, but most just stack them on top of shirt piles and move them along with the goods.  With today's technology, why would anyone do that?  Because, it has always been done that way and it works.  Most of the time.

But there must be something better.

Ok, sounds catchy.  But what does it do?

Linx is a production management software that pulls orders from your online site, sends them to preset stations and pushes them into shipping.  The only thing that is printed is a barcode sticker that is attached to the garment.  It gives all departments including the artist, purchasing, production and shipping access to the order with the ability to sort all orders by the information that is relevant to that department.

The Linx app keeps all departments connected and can be integrated into most parts of the imprintables industry.  This system can be connected to DTG, laser engravers, plotters, and many other decorating operations.  

With this available, why would you want all that paper?

DTG curing for community printers

BrownDigital offers some amazing machines for large volume DTG producers.  Between the FireFly, the DragonAir Griffin curing systems and the Synergy pretreated production capacity is high and expandable.  These systems provide high quality finished goods as well as volume which have made them mainstays in these shops.

But what is available for the smaller or community producer who needs to be faster than a heat press allows?  Or one who would like to increase their quality to satisfy a higher lever customer?  BrownDigital offers curing systems for those DTG printers as well.

DragonAir Fire

DAF-3611 DragonAir Fire (aka Black Dragon)

The DragonAir Fire is offered in a 36" x 11' configuration.  Standard features include:

• DragonAir Core Technology
• TRX software for control of all curing variables 
• Adjustable heater height
• Adjustable convection air
• Digital belt speed control
• 8" heat bump with adjustable temperature control

DragonAir Core Technology 

The DragonAir Core for this system features air that circulates within the heated chamber and is scrubbed with filters.  The water vapor is exhausted from the chamber to increase the cure rate.  Adjustable heaters allows for different substrates and different ink density.

TRX Main Running Screen

The software feature on the Fire is one that sets this apart.  

• Storage of up to 36 production profiles
• Touchscreen adjustment of all variables of garment cure
• Analytics of production costs 
• Storage of up to 18 maintenance tasks
• On board diagnostics
• much, much  more

DragonAir Crimson

DAC 2406 DragonAir Crimson

This baby dragon is new to the BrownDigital product line.  Offered with a 24" wide by 6' long belt, it can be expanded by adding additional chamber.   It offers the main feature of DragonAir Core Technology at a cost that is appropriate for smaller shops.  Hot air is recirculated through the chamber to cure both DTG inks and pretreat.  

Crimson Features include:

• DragonAir Core Technology
• Digital temperature control
• 4" heat bump with temperature adjustment
• Adjustable convection air

Is DTG for you?

So if you have one digital printer or many BrownDigital can improve your production flow with a curing system that is within your price range, production requirements and space restrictions.  Contact us to talk about which system is best for your bottom line.

DTG curing systems are different, and need to be.

Not your grandpa's t-shirt dryer

Digital printing is a specialty market requiring a new way of thinking.  Rapid production of low volume, high quality graphics is necessary to produce high profits.  The DTG printing process is different than traditional decorating.  The chemistry of the inks and pretreat require new curing temperatures and times.  They also need a different type of cure.  Traditional IR heat with a little moving air just doesn't do the job.  This technology is designed for plastisol and, though it can be used for DTG, it will not give the best results.

So what's different?

Let's start with pretreat.  What is it?  

Pretreat is a sticky liquid that mattes the fibers into the garment to create a flat, smooth surface for printing.  Most pretreat needs to be sprayed onto the garment and then heat pressed to get the best results.  This process is slow but effective.  Conveyor ovens, if designed for the job, offer a faster process with fewer operators.  Pretreat needs heat and air.  Evaporation is essential.  So, convection heat is optimal.  The garment still needs a 3 second press after exiting the oven to flatten the fibers.  What a convection oven offers is less standing around for the operator.

Now the ink.  Water based and white under base passes make this more complicated.

Water based inks need lots of air flow and time in the chamber.  Water is slow to evaporate and the chamber needs to evacuate the water without pulling out the heat.  Temperatures are lower than plastisol but times are longer.  Traditional ovens boil the water out with direct heat and evacuate the air with standard exhaust.  

The white under base, which can have multiple passes also needs to get the water evacuated.  This increases the time in chamber but the top color passes cannot handle the extra heat, so convection air is the optimal solution as the garment temperature stays more stable.

Why not use what you have?

You can.  And we sell ovens that will work if that is your best plan.  Yes, the TRX, the UltraSierra X-Series 2, the AirBlazer and the AirPony can cure DTG inks.  And they are a lower cost than ovens specific to DTG.  So if budget is a concern, our years of experience can help you use plastisol technology for your digital prints.  

However, we do not recommend them.  

Why?  You say.  No, it's not because we want to sell higher priced stuff.  It is because the technology to cure plastisol inks is not the same as the tech to cure digital inks.  Traditional ovens, like the ones we have been building for over 30 years, are great at what they are designed for.  They ramp the temperature of the garment up as they radiate heat directly onto the ink.  The ink does not need to evaporate, it needs to cure.  Plastisol inks, generally, require a cure at 320°F through the ink film.  As long as the full ink film gets to this temperature without scorching the garment, you can go as hot and fast as possible.  Once the plastisol hits temp, it becomes a solid sheet of plastic that is adhered to the garment.  So air is a nice feature to reduce hot spots in the oven or to force air into specialty inks like puff.  However, it is not needed for cure.

Options?

Gas ovens are a possibility for both ink types.  They are convection systems that sit the garment in hot air and evacuate smoke and steam.  However, in order to get to temperature, they need to be large.  Most shops do not have the space or budget for these ovens.  They also require a large power supply in addition to the natural gas connection.  In order for the garment to get to temperature quickly, they often have an IR bump in the beginning of the chamber and this requires 240V power.

So what do you look for?

Heated air, and lots of it that is contained within a closed system that scrubs and reuses it.  Another necessity is a quick blast of heat to bring the garment up to temperature quickly.  The fast temp bump will get the garment hot before it sits in the heated air which will speed up the cure time.  Additionally, that heat needs to stay in the chamber.  So cool external walls will keep the chamber hotter and the work environment cooler.

Digital temperature controls are essential.  Since garments are in the cure chamber for a longer duration than traditional curing, maintaining the top temperature will speed up cure and avoid scorching.  Digital controls maintain chamber temperature ±7°F and this will alleviate any cure concerns.  

Belt speeds that are slower than traditional plastisol cures are warranted as well.  Our pulse generators allow for belt speeds as slow as 99 minutes in the chamber.  Plastisol cures are 30 seconds to 2 minutes.  DTG needs 2 to 6 minutes depending on passes and the amount of pretreat.  

BrownDigital

DragonAir Core Technology

The DragonAir line of curing systems is designed for digital, water-based, plastisol, polyester, and specialty printing for fast paced, high production shops.  The DragonAir Core Technology™ ensures consistent and complete curing on all garments.

The new Crimson Dragon is designed for smaller shops with singular DTG devices.  The offer DragonAir Core Technology as well as digital temperature control in a compact footprint.  Priced for community printers, this allows a screen print shop to install a small oven just for DTG.  

The DragonAir Fire is for larger DTG producers who need additional belt space and are looking for higher end controls.  They feature TRX software for full control and storage of up to 18 separate garment profiles.

DragonAir Griffin systems are for full DTG producers.  Expandable and utilizing TRX software technology, these dragons give flexibility and durability for the ever growing digital market.

The FireFly is patented technology that goes one step beyond the Dragon line.  This revolutionary system will allow any type of garment to cure through any belt at any time.  Thermal imaging cameras monitor and adjust for each garment as it travels through the oven.

Not your grandpa's t-shirt oven because these are not printed on your grandpa's carousel.  Advancements in the industry push all of use to create new technologies to accommodate.  Look at your production facility and see if old school is still best.  It may be, or not.

Is it time for an automatic press or a DTG?

Decisions, decisions.

If you have the time to check out our web sites you will see that Brown Manufacturing offers a wide range of decorating machinery.  We build small screen printing machines, automatic screen printing machines and large production machines for direct to garment printing.  So, with that diversity we get to talk with a wide range of customers and this gives us a unique perspective on the industry.  The question of when to invest in different production machines is posed from all levels of decorators.

Manual and DTG to automatic.  When is the right time?

When chatting with a small community decorator, the talk of adding an automatic or DTG printer is common. Typically, a shop starts with one DTG system and a heat press or a manual screen print set up.  Sometimes a combination of the two.  This configuration is designed to be a one-man show with low rent and no employees and sometimes, no paycheck.  As this business becomes more successful the need for higher volume pushes for the choice of hiring employees or buying automated equipment.  There are some screen printing production numbers that make it clear that adding an automated press is more profitable and less stressful than adding an employee.

35 hours manual vs 8.5 hours auto

Based on these numbers, a one man shop can produce a weeks manual work in one day.  This allows for growth without added payroll or time off if you are worn out.

ElectraPrint Junior

In some cases it is a DTG shop turning to screen printing.  This conversation is typically driven by volume.  The production rate of a DTG machine is lower than a manual print shop but the time constraints are similar.  So the question is whether each run justifies a different type or printing, or are the jobs still low run but there are a lot more of them.  If the runs are longer, then an automatic screen printer is the better investment.  A GTX produces 25-30 shirts per hour.  Any run that is more than 20 shirts could be set up and printed in less time on either a manual or an automatic press.  Yes, there is the screen printing mess and labor question.  However, the labor is the same.  One operator per machine.  Also, with the pretreat and the multiple steps in a DTG print, the mess is not that different. 

If the problem is with more short run jobs, then additional DTG machines should be considered.  With that in mind, how that DTG production flow is managed should also be studied.  There may be more involved than just the printer.  Look at the curing systems, the pretreat application systems and the artwork management processes.  There are products that make all of these tasks more efficient.

When do you add DTG?

Synergy Pretreat and FireFly Curing System

That questions is more about adding a profit center than changing production styles.  If your business has potential in the one-off or customization market, then a DTG adds another dimension to your offerings.  If your screen printing presses are full with longer runs, then a DTG for the short runs is an option to consider.  These systems can be run with less skilled operators and require little working space.  They are serious profit centers when used for the correct market.

At what cost?

Automatic screen printing set ups and digital printing set ups are similar in price.  Each will run from $25,000 to $35,000 once you include all the details.  Yes you can buy less expensive systems, but you do get what you pay for.  This capital investment comes with one strong benefit.  With proper maintenance, it shows up every day for work.  And, without any additional fuss, it allows for growth in either volume or product lines.  A positive investment in either direction.

Let us know when you look at the expansion.  We can help you cost our your options and we look forward to hearing from you.

Firefly curing systems for screen printing

Though the FireFly is often paired with our Synergy for DTG production, the system was originally designed for screen print applications.  At the time the product was developed, the athletic printing world was challenged with an influx of polyester garments that had a high level of bleed issues using standard curing technology.  Additionally, water base and discharge printing was on the rise and typical electric ovens did not offer enough air flow to cure these inks effectively.  The FireFly offers unheard of solutions to both of these issues.

Ink manufacturers have developed dyno-gray inks to block dye migration in the polyester garments.  These are pricey and add one more color to many designs.  We have seen one job that appeared to be 2 colors actually be 3, but needed to be printed on an 18 head press to get the best results.  The Firefly allowed for the removal of the dyno-gray because the system is in full control and is responsive of garment temperature throughout the curing chamber.

How does the FireFly do this?  Thermal imaging cameras monitor the temperature of the ink and the garment with constant feedback to the software.  This feedback directs the controls of the quartz heaters to constantly modify their heat to keep the shirt within required parameters.  This control keeps the shirt below the dye migration temperature.

Also, the water based inks and discharge inks require large amounts of air for each garment as well as the solid control of garment temperature.  Air flow within the chamber is specified to each garment and is separate from the heat directed on the garment.  This allows for rapid evacuation of water vapor as well a quick cure of the ink.

Brown is thrilled with the connection of the FireFly in the DTG world.  But we are equally pleased with the long term reliability and curing diversity that the unit has provided our screen print customers.  Multi-variate printing is the mainstay of this system.  And that is the screen print world.