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.  

Brown is our name, but we are open to other options

 An army of machinery. And some are painted Military Green.

We have done some fun custom colors in the past.  Bright pink, red, purple and blue have all popped into our assembly line as customer request.  This is our first military green.  

The whole shop for this customer will be color themed.  

If this is a feature that interests you, please contact us for information on how we can custom paint your machinery to make your production part of your showroom experience.

2022 brings big changes for Brown

 Go big or go home.

As the old saying goes, Brown chose to go BIG this year.  We have expanded our space, our people and our product line.  We also added a few colors to the Brown machine pallet for a little fun.  With expansion comes change and a few bumps in the road.  But our staff was ready for a few challenges to get us through.

BrownDigital has a developing partnership with Brother International.  This partnership has fostered new product for the Print-on-Demand world that Brother specializes in.  The POD sales strategy is immediate delivery of one off printed items.  Garments have a large segment of that market and they require a few additional processes compared to other one-off pieces.  This rapidly expanding market requires faster machinery to keep up with the volume and Brown delivered with the DigitalLine, an exclusive product for Brother.

The size of this system required additional assembly space.  So, Brown added a Crown.  Well an address on Crown anyway.  The added space has allowed all of our production departments to stretch their legs a bit.  As an example, where the space on Stafford allowed for 2 Electraprint machines to be assembled at the same time, this new space allows for 5.  As well as multiple manual machines and curing systems.

Your staff appreciates the space and is looking forward to upping the volume to fill the new building.

The fun of the Electraprint and Brown lines has been the "choose your color" option that we have introduced.  We have assembled a variety of colors in 2022.  Bright red, hot pink, military green have been shipped as well as the tried and true chocolate brown.  Do you have a color scheme in your facility?  Need us to match it?  We are on it. 

One other expansion that is a direct result of the POD market is the addition of new software modules available for the Linx Production Software .  In addition to the already stellar workflow application, new modules for inventory management, purchasing and QuickBoook integration have been developed to fill the every changing needs of our POD customer.  Contact us for additional information on how Linx can improve the work flow and organization within your production floor.

The new space and the new offerings have made our lives a little stressful (as moving often does) but the impact of the change and the production results just keep showing us that this was a well needed expansion and that we have more room to grow.

Getting creative during the supply chain crunch

For anyone who is chasing garments of every type and style, we understand your pain.  The supply chain issue is applicable to everything from ramen noodles in the grocery store to automobiles.  It is not just the finished products, but the raw materials and the sub-assembly items.

So what to do?

Get creative, that's what.  We have had conversations with customers who tell us that they have called 7 vendors to fill one order.  Or that they have converted brands to fill the order and told the customer that the original brand was unavailable.  Or they have had to start from scratch with the sale to find items that would fit both the customer and the supply chain issues.

Well folks, it isn't just shirts.  Anyone who needs a new car will know of the shortage of electronics that has stopped car production.  Or chat with someone in the foam industry and they are out of the base chemical to produce styrene box inserts.  Or try to find copper wire to install new power drops into a facility.  The list is long and diverse.

In our world, we struggle with it all.  Electronics to wire to small basic switches.  The largest eye opener is DC motors.  The screen printing industry, as a US whole, uses the same couple of motors on all conveyor ovens.  It has been this way for over 30 years, so all of the ovens in the field also use these motors.  Guess what.  They are not available.  So we have had to get creative.  We have sent customers to motor repair shops.  We have offered used motors at a drastic discount.  We have upsized motors and sent additional mounting brackets to make them fit.  We have found alternates that need new brackets but will work.  Anything to keep our customer's production running.

Just like you, we are going to great lengths to keep our customer's machines running.

Changes coming?

China, who is is one of the US largest trading partners, continues to shut down full sectors of their country.  While this continues the world will see additional shortages depending of what items are produced in those sectors.  

We want our customers to be aware that supply chain issues run deep but that the Brown team is working diligently to keep your shop operating at the top level. 

 

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.

When to update to new stuff?

Tech changes every day.  Our fast paced world is presenting us with new, and better, ways to accomplish most things on an hourly basis.  Some of this is very intriguing such as electric vehicles or 3D printers.  I do get annoyed, however, being told that I have peeled a carrot wrong my whole life and this new hack or tool will be the only answer.  And though I am sure that my carrot peeling skills are just fine, at what point does the machinery in my shop need to upgrade?  When is the new really better than the old?

What can the new tech do?

If the new gadget is cooler looking than the old one you might be inclined to switch.  Aesthetics in an automobile are important.  We all like new, shiny things.  However there are certain requirements that make a new device worth adding to a shop.

• does it make a process faster?
• does it reduce costs?
• does it make a final product better?
• does use less floor space for the same results?
• does it require less power for the same production?
• is it easier to use?

There could be more to the list, but the idea is that a new gadget needs to improve production either with cost or quality or time.  If it does not do any of these things, just wait.  Another version will.

What does the new tech NOT do?

Yes that is important.  If the new item does go faster or reduce costs but it makes an inferior product it is probably not worth the investment.  If it goes faster and makes a great product but the cost makes the RIO low, then it is not worth the financial outlay.  If it does not do all the steps in production that the current version can do, then this is not a gain.  New is not always better.

When should the old tech go, no matter what?

I say that with some wisdom.  As a manufacturing company who has produced machinery since 1979, we help people every day fix stuff.  We offer free phone service and with the use of digital photos, Zoom and FaceTime we are able to fix most old machines.  Many times that repair is priced quite reasonable and the customer keeps using a machine from the 80's.  

However, sometimes old is old.  Broken is broken.  And being thrifty (read cheap) does NOT help your bottom line.  Maybe you can get the parts for a 1984 machine.  However, how long were you down waiting for them?  How long did you have to search for a supplier for them?  Are they the direct replacement or did you have to modify the machine to make them work?  All of those items cost money.  Down time means late production.  Your search time means you did not spend time making sales or managing your production.  Modifications to old stuff takes both your time and down time and they are never quite what you needed.  Is that cost beneficial?

We do understand small business and the need to keep costs down.  We understand budgets.  We also know that if you have big equipment with big repair bills you have a hard time paying, then your really needed smaller equipment to suit your space and revenue.  Crunch those numbers sometime.  You might be surprised to find out that that big stuff you bought at a great price is costing you more than you make and newer smaller stuff would make you more profitable.  Hard to fathom sometimes but it is true.

How can we help you figure it out?

Most people do not like to discuss financial situations with sales people.  But the truth is, good sales people want to see their customers succeed and make money.  Think about your own style.  You want to have return business and you treat a customer with the goal of seeing them again.  Capital goods sales people are the same.  We would like you to buy well so you do well.  Then call us again for the next cool tech item that you are interested in.  So consider sales people as allies who gain when you gain.  Ask them if it is worth it to keep with what you have or go new.  Yes they will pitch new as hard as they can.  They have kids to feed, just like you.  But good ones will help crank the numbers to see if the justification is there for your shop.

You might be surprised by what you learn.

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.

Start your engines. The season is about to begin.

 Are you ready?

The season is about to begin.  It has been a long time coming but it is finally here.  Are you ready?

What exactly does that mean?  Are your machines ready for all the action about to happen?  Let's go over what you should be doing now so you are ready for all the orders that are coming your way.

Check under the hood.

Conveyor ovens

Your curing system is the most important machine in the building.  You can print in any number of ways.  But getting a shirt cured has limited resources.  So keep your conveyor ovens at optimal performance levels.  How do you do that?

• Clean it.  Yes, it is the most important thing.  Get all the fuzz off of it and out of the control panel and fan systems.  The biggest reason for oven failure is overheating due to lint build up and fan functionality.  So get out the shop vac, open the control panel and clean it out.
• Replace stuff.  We understand that in low times, the cost of replacement parts can seem prohibitive. However, if you are down during the busy times due to lack of maintenance, the cost to the business is higher.  Cooling fans, old drive motors and dirty or torn conveyor belts are quick to change and will reduce down time during high volume months.
• Have commons part parts on hand.  Some items are low cost and quick change.  Having these items on hand will lower any downtime. Relays, heater connectors, fans and fuses are small and inexpensive.  These are highly recommended to stock on your shelf.
• Check out the drive system.  Worn sprockets and chains will cause power spikes that will damage a motor control.  This will double your replacement cost.

Automatic printer

Unless you want to manually pull a squeegee on the long run you have, you should spend a little time making sure that your Electraprint is running well.  There is a reason that it asks every time it turns on, "Have your greased me today".  It is important that all the moving parts on the machine have lithium grease applied and lint removed.  This includes squeegee carriages, head side rails, cheese wheels and lift mechanisms.  There are a few other items on the press to check.

• Squeegees and floodbars need to be sharp and smooth.  No nicks or dull edges.  
• Have some extra squeegees because color changes just slow you down.  A squeegee for each color group is a great investment.
• Platens are clean and the rubber coating doesn't have bubbles or tears.  A great print happens on a flat, smooth surface.  Don't skip on the basics.
• Chains and motors and sprockets do wear.  These are what drive the print heads.  Check now while you have time for a sprocket change.
• Clean it up.  Seriously, clean shirts come off clean printers.  And it is the cheapest way to keep a press run smoothly.

What should be in on your parts shelf in case of a pit stop?

Each machine has some essential items that cannot be bypassed.  And many of these are inexpensive so having them immediately available is like having a spare set of tires ready when the car rolls into the pit.

Dryers

This is all about moving electricity.  Simple parts will keep an oven rolling until bigger items can arrive.  

• Fuses or panel breakers
• Power breakers
• Relays
• Terminal blocks for older heat chambers

ElectraPrint Automatics

• Photo eyes -- there are a couple of types, so have one of each
• Safety switches
• Flash controls
• Head cable set

What tools are needed for the pit stops.

It surprises us often that many of our customers own industrial equipment but do not think to have a basic tool box anywhere in their shop.  This does not need to be an extensive set of tools, but some basics are needed to keep a shop rolling through a pit stop.

• Open end wrench set
• Socket set 
• Screwdriver set
• Nut driver with 1/4" socket
• Basic multi meter.  Our phone techs can teach you to use one, but they are really handy when working on anything electrical.

So get ready to race.

Order some inks, get your screens stripped and coated and set out your print stations.  There is business in the air and the race to the finish will be a wild one.  Let's not have any crashes into the wall.  We will all get to the finish line.  

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.

Used versus Reconditioned. What's the difference?

One thing that 2020 has created is opportunity.  No, we don't hear that very often right now, but 2020 created expansion in some sectors.  The POD (print on demand) market is exploding and that benefits the direct to garment decorator.  Masks are a new product all-together with a need for everyone to own many, so corporate branding is essential on these.  This benefits both the DTG printer as well as the direct screen printer.  

One other market that is growing is the used equipment market.  With the rapid shifting in the global economy, many printers are dumping their current machines due to loss of business or change of direction.  These machines are both manual and automatic printers and curing systems for large and small. Much of the local business is still available and new small printers are looking at that opportunity with the idea low overhead by working without store fronts or from home.

Do you buy Used?

Used machines are like used cars.  They are being sold for a reason.  And even when the current owner says, "it ran great yesterday" there are issues.  Many times these issues are easily fixed if the cost of the machine is within budget.  When buying, each machine type has different functionality to pay attention to.

Manual Printers

When looking at manual printers, most things are fixable at reasonable cost.  Just make sure the cost of the press is minimal.

• Are the platens in good condition?
• How clean is it?
• Do the print heads come down and seat tight within the registration gate?  And if not, is the gate adjustable?
• Do the micros work?
• Are the head lifts strong, springs or gas shocks?  And if not, are they still available?

Automatic Printers

When looking at auto printers, replacement parts are costlier.  Also, if you have never set one up and want a tech, make sure one is available and that you are aware of that cost.  Covid-19 has limited travel and increased these prices.

• Are the platens in good condition?
• How clean is it?
• Do the print heads come down and seat tight within the registration gate?  And if not, is the gate adjustable?
• Do the micros work?
• Are the motors or air cylinders in good condition?  This can be a very expensive fix.
• Are there squeegee and floodbar sets?
• Does the flash work and what power is required?
• If this is an air driven machine, do you have the power to run the compressor?

Curing Systems

Dryers are the mainstay of production.  Used ones are available everywhere.  And these are tricky to determine if they are fully functioning.

• How clean is it?
• Do all the heaters turn on?
• Does the belt run and how old is the drive assembly?
• What is the condition of the belt?
• Does the air system function?
• Does the oven have digital controls?  If so, these are more expensive to repair.
• Is this manufacturer still in business?  If not, replacement heaters will be difficult to find.

What does Reconditioned mean and is it worth the cost difference?

Reconditioned machinery from Brown has been inspected from top to bottom.  We will admit that we do not clean used machines as we do not want to charge for labor that the end customer can do themselves.  However, all machines are inspected and repaired for all specifications.  Parts that are marginal are replaced.  Wiring in all ovens is inspected and replaced, if necessary, through the heater rack and into the controls.  Heaters and motors are replaced if they are not functioning.  Control panels are rewired and updated to current technology.  

What is all of this worth?  That is up to the buyer.  Our machines are more money than used ones.  However, we know they will work when you get them and Brown provides a 30 day warranty on the complete machine as well as a 1 year on any item we replaced.  That is a reassurance that pays off in production time and your potential profits.

If you are looking at a used machine, contact us to see if that machine is priced where it should be.  Ask us for the potential repair parts costs.  And then see if we have a comparable item that is reconditioned.  You can determine what value that is to you  But we believe that downtime costs more than any up-charge of refurbished.

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.

Being prepared is a profitable idea

Dreaded downtime

Downtime due to machinery break down is a killer for the bottom line.  Not only do products not ship, employees are not productive.  This translates into an increased cost of goods and a decrease in revenue.  This is a big problem for both large and small producers.  Small producers, even if they are paying themselves and do not track labor costs have a decrease in revenue and a potential loss of a customer.  Larger companies track worker productivity as it relates to job costs and overhead.  As the ratio changes due to machinery downtime, profits suffer.

The solution for much of this is simple.  First, all production facilities need someone that has an understanding of the maintenance required for all of the machinery on the production floor.  This includes the simple items such as cleaning, lubrication and calibration.  Additionally this person should be handy with tools.  In most cases, these are difficult tools.  Simple wrenches, screwdrivers, wire cutters and a crimping tool, and possibly a multi-meter will do the trick.  

 Additionally, there are always a few items on all machinery that are essential for them to operate and cannot be bypassed.  If your production is reliant on any machine, then having these items in stock is a wise investment.  How much does this cost?  You would be surprised at how little, especially compared to the cost of downtime.

Midline Printer

LED Exposure System

As a suggestion, a manual printer will operate without any inventory readily available.  If they use a gas strut to support a print head, keep in mind that these have a limited life and having them available after about 2 years is a good idea.  These items are about $50 so this is minor.  An exposure unit will need a bulb at the 2 year mark.  So be prepared.  This can cost between $70 and $300 depending on the bulb.  New LED style units will not have this issue.  But a vacuum motor and timer are another part of that unit is essential.  If your exposure unit goes down, are you prepared to not process screens for 3 days?  The entire package of parts should cost less than $350.  

AirPony Dryer

Conveyor ovens are another issue.  If your shop only has one oven, your production hinges on the function of this machine.  Most systems in a conveyor oven can be bypassed to get a production floor moving.  However, the drive system cannot.  So, a drive motor and a motor control would be excellent items to have on hand for any over over 2 years old.  Again, the cost is minimal compared to the impact of zero production.  If you print garments that have a rigid temperature requirement, then stocking temperature controls is also a wise investment.

ElectraPrint Stealth Series

As for automatic printers, this is all dependent upon which type you are running.  For the ElectraPrint, we recommend a few minor items.  Photo eyes are handy, but typically the press can run with exchanging parts between heads.  With air machines, extra air cylinders are a wise choice.  Though, again, you can borrow from one head to another, having a set of cylinders is smart decision.

All machinery will have wear parts.  Just like a car, oil changes will keep a car going for many miles, but at some point, things need replacing.  Plan ahead, stock a few things and be prepared.

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.

What an amazing year of innovation and learning

2018 has been an amazing year for Brown and BrownDigital.  It is difficult to list all of the changes that have occurred because it is not often that a company is cascaded with growth, innovation and industry accolades.    Our product lines continue develop and reach into new business sectors that originate within the garment decorating world but now sector off into many new specialties.  Our traditional Brown line has combined with the newer BrownDigital catalog to connect us with new people and our existing customer base with new advancements.

Since the screen printing sector of the industry remains strong, our ElectraPrint remains a solid base for our Brown product line.  The easy to maintain design, simple operation and durable construction  continue to make them a product of choice in the industry. It is always a pleasure to have a customer return to add another machine to their production line.

Many of these traditional printers are now expanding into the digital printing world and BrownDigital is there with solutions to these production issues as well.  The patented FireFly system is the technological leader for curing of both DTG and screen print inks.  The thermal imaging camera innovation sets this product apart from any other in its category.  This product saves space, time and energy while providing flexible curing for any garment at any time.   Combining the FireFly with the Synergy pretreat module adds another level of production control and  flexibility to any direct to garment printing operation.  This complete system is the reason for the expansive growth and reach of new markets that we have enjoyed in 2018.

The pinnacle of this is the SGIA's prestigious Product of the Year awards.  Brown Manufacturing Group is honored to have earned these award for 2 years running.  We show distinction in curing, pretreat and combination systems that cover an array of production variables.  What is still more exciting is that our engineers have more innovations ready for to present for this award next year and still more to come.  The buzz of ingenuity in our office is energizing.

So thank you to our loyal customers for their continued support of the Brown screen printing product line.  We see this part of the garment decorating industry to remain an elemental part of our business for years to come.  And, to our new DTG customers, welcome to the Brown family.  We look forward to continued success and connections within all sectors of our industry in years to come.

Our industry is unique, and challenging

I met a friend for cocktails this weekend and we discussed our careers and the industries that we are in.  This person had a recent job change and was describing the differences in the two markets.  While chatting, the question came up, "Why is printing on a t-shirt so hard?"  It occurred to me then that what we do is truly unique.  In most industries the production variables are limited and consistent.  The "how to" is measured and analyzed with tolerances defined and universal industry standards measured.  Well, anyone who has printed garments knows that most of this does not apply to us.

Sure we have defined cure temperatures for ink.  Sure we have PMS color matching.  And, of course, we have production rate requirements.  But even all of this is loosely followed.  Ink cure temperatures rates vary by brand and type.  PMS colors are borrowed from other print industries and are loosely applied to color cards from ink companies, though many shops do have custom ink mixing in house.   As for production rates, we are all trying to produce a profit.  And that need drives everything.

So my companion currently sells high end cars and used to sell real estate.  Market and economy fluctuations are what drives these industries.  In the metal fabrication business, metal is systematically measured and variables in quality are based on the human factor.  The inkjet, laser and DTG printers that surround my desk are all assembly line production items as is the laptop I am writing with.  So I explained all of the options within production and sales of printed garments and I mystified myself with questions of how we do it all.

Let's go over the list.

• Every garment type is different:
  
• color
• fabric
• weight
• pile
• construction
• Every individual garment may be different:
• size
• Every ink type has a different cure temperature and that is influenced by:
• thickness of the ink film
• thickness of the garment
• number of layers of ink film
• time in the chamber
• temperature of the chamber
• air flow of the heat chamber
• Each artwork file has it's own printing parameters
• size
• number of colors
• type of separation
• what color it is to print onto
• Type of printing influences or is influenced by all of the above
• Manual screen
• Automatic screen
• DTG
• Sublimation
• DTG variables include
• pretreat type
• pretreat density
• pretreat cure

I have only scratched the surface of what can happen in a day.  So what do you do?

You can go old school.  And it works.  

Log books, spread sheets, paper pick tickets with instructions, even sharpie marker notes on the machinery can help limit issues.  As an example, a pick ticket should include order information, cure settings, pretreat requirement, ink colors and color order.  This is a solid system that works most of the time and is historically reliable.  

Now let's move that to today's technology.  

Digital resources make it possible to put every piece of information in one storage location and link all that together by all the variables.  This can all be put on a mobile device at each production unit that can reference the information by scanning a barcode.  This technology is used in most production industries today and, because of all of our variables, should have been in garment decorating years ago.

A previous blog was written on our Linx software.  This system manages the information on all of the variable that are listed above.  Once information about a type of garment are input into the data base then that information is linked to any order that needs that garment.  It stores artwork files and connects them to orders.  It controls curing and pretreat parameters in the Synergy and FireFly.  It can track orders through production and connect them to ShipStation.  This tool helps to contain the chaos that is elemental to garment decoration.

So, though the cocktail and conversation was a wonderful way to catch up, my companion decided that what I do is crazy talk and selling Porsche and Bentley are a better fit.