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.

ElectraPrint BP introduction

 You asked for a 12 station ElectraPrint!

ElectraPrint BP 10 color 12 station

The ElectrPrint series machines has been a perfect fit for community printers for many years.  Starting with the Junior and the Stealth machines, Brown has delivered low maintenance high quality production machines to shops all over the world.  Many of our customers have requested we expand the line to allow more colors.

The BP series is available in 8, 10 and 12 station machines in both the Junior and the Stealth machine sizes.  This allows for more colors in small spaces, with the Junior.  And for larger prints using the Stealth.

The BP series provides all the features you have come to expect from the ElectraPrint line of machines.    This machine is fully electric with easy to understand controls.  iMade is a standard feature as well as skippy platen sensor and flash ports on every head.  

The LazerLoad feature, the Set-N-Go and the QuartzAir Flash are all available options for this machine as well as a wealth of different platen sizes.  

For more information on how this fits into your production space, contact your Brown Team or give us a call 616-249-0200.

For Brown, it is all about customer service

When a person calls Brown Mfg they get a person.  We do not use automated attendants or voice mail on our main phone system.  When someone sends an email to what appears to be a generic email address such as sales@brownmfg.net or customerservice@brownmfg.net or linx@brownmfg.net those emails land directly in a person's inbox so they can be addressed quickly and directly.  These corporate choices are based on the elemental belief that direct person-to-person interaction provides the highest quality service to our customer.  Call us old fashioned, but we get thank you comments from our customers on a daily basis.

Another customer service item that we offer is custom paint as an option for new machinery purchases.  This generates excitement for people who have their machinery as part of their customer's experience.  These businesses sometimes have a production shop as a showroom and they have a corporate color scheme to match.  Recent colors have included combat green for a customer who services military families, hot pink for an all women's shop, and red white and blue because,  well, just because.  

One added benefit item we offer is creative installation solutions.  We cater to community printers. These are typically businesses with very limited space and often owner/operators of the machinery they buy.  Their production spaces are often not commercial, do not have loading docks and many times are multi storied.  One ElectraPrint leaving this week is no exception.  This installation involves a set of stairs into a lower level with 36" doorways.  

To accomplish this task, we take the machine apart into manageable pieces.  The base, the print hub and the platen hub are all packed separately.  The heads, platen arms and accessories are on other pallets.  

Our installer has tools available to assist with moving these pieces into tough spaces and to reassemble these pieces in the final location.  Once assembled, the installer will continue with the standard installation process and training of the customer.  

Yes, this is a fun one.  But not unique.  We have many stories of fun installs.

So, if you are thinking that it is time for your shop to step up into an automatic press but you are concerned about how it will fit into your space, contact us.  Brown has solutions.  We also have over 50 years of experience at these creative installations.  We are here to assist you, person-to-person, in making your business more productive and more profitable.

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.

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.

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.  

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.