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.

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.

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.

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.

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. 

 

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.

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.

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.

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.

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.

 

 

Set-n-Go. Go where? No, go faster.

Every manufacturer of printing equipment touts a pre-registration system.  This is not one of those "do you want fries with this" kind of items.  It is a serious tool and we think that it is a necessary piece of equipment whether you are printing manually or on an automatic.  Old school printers and many do-it-yourselfers will say that this is unnecessary because they are so fast in set up, but experts disagree.  These systems have gotten so elaborate that you can purchase printers to put the art exactly on a screen so that press registration upon set up is perfect.  These high end systems would not be developed if they did not have major benefits that offset the costs.  They will cut your screen set up time on a multi-color job down to 5 minutes.

Time is money

Speed and accuracy, my friend.  Speed and accuracy.  Hypothetically, if artwork were always placed in the exact same spot.  If screens were loaded into the press in the exact same spot.  If artists registered the art to the final garment each time.  Then job set up would be so perfect that press adjustments would not happen.  Imagine the speed.

• Little to no micro or macro adjustment of the press
• no platen adjustment
• no checking of the artwork location on the garment and adjusting to fit
• straight prints all the time without hassle

Yes, some of you will say that you never do any of these things.  Seriously, we know you do.  That is why we put all of these adjustments on a press.  However, we know that all of these adjustments will cause set up for every multi-color job to be a minimum of 15 minutes.  

How does it help?

By starting back at the art department, a set of predefined art locations will cause the artwork to land on the correct location on each garment without adjusting the platen or the garment upon load.  

If the Horizon line of your artwork represents the collar of the garment, the the artist has a good starting point of knowing where to place the art.  General rule is that there is a 3" gap between the collar and the top of the art.  Also, if the Horizon line is also the top edge of the platen on the press, then you can say that all garments load so that the collar just falls off the platen.  If the artist and the printer match, then the operator only needs to load the screens a to the preset stops and the platen will not need adjustment.  This is the same for all art locations.  Preset the location of the pocket or the back print and allow the collar to always just fall off the shirt board.  This simple rule of preregistration systems saves time on every job.  No more guessing of platen location.  No testing of shirt load location.  No wondering this run will match the previous run of the same job.

How do you get the screens exposed correctly.  

Let's think through the next steps of the process.  The artwork comes from the art room with horizon lines and registration marks on each film.  The platens are fixed in location.  Now if every screen is burned using a fixture that matches a fixture on press, then set up is a breeze.  And by fixture, we do not mean a t-square.  We are looking to speed things up, not slow them down.

The screens go on a jig, the art matches the jig.  Process the screens and then load them against the jig that is on the press.  Sounds clean and simple, right?  Ok, let's slow this down and list this out.  The artwork is set against a standard registration template so that template should be affixed to the screen box.  In some systems, there are pins that the artwork sits on.  In some, the fixtures are on the exposure glass.  In ours, the template is adhered to the yellow box.  The screen seats agains the guide pins and then the art is taped on while matching the template.

Once the screen has been processed, the screen is set into the press against a guide pin bracket.  This bracket flips down so that it stays on the press but is out of the way of the operator.  Check out this video for a quick "how it's done".

Yes there will be some short term time spent on learning new steps.  However, if the press set up time drops to under 5 minutes, then the value of the system is justified.  The faster we move a job through the shop the higher the profits.

Preparing for new equipment installation

Growth and expansion in a business is driven by the arrival or hope of new customers and orders.  This justifies the cost of new equipment in all levels, whether a new exposure system that allows for faster screen production, a new DTG to expand into new markets or a new automatic press for quicker turn around.  This expansion is exciting and trying times and there are some tips for preparation of installation of the new equipment.

What to expect upon machinery arrival.

Depending upon what is coming, a machine may be installed by your own staff or it may need a technician.  However, one this is certain.  It will arrive on a truck and it will be heavy.  It will need planning for the unload and connection.  What exactly does that mean ?  It means understanding how to get the product off the truck, having a door and path wide enough for the equipment to reach its final location, having utilities and services ready and finally having people on hand to help.

If it is coming on a commercial carrier.

Common carriers, those are the semi-trucks seen on the road, then accommodations need to be made to get the machinery off of the dock high truck and onto your production floor.  If your location has a dock, then a pallet-jack is typically sufficient to unload from the truck.  If your location does not have a dock, then there are a couple of options.  First, a lift gate can be requested.  These are an additional cost and additional delivery time.  Also, if the crate is larger than a 4' x 4' area, then a lift gate will not be large enough to handle the skid.  Second, a fork truck can be rented and the crates can be lifted from the back of the truck to the ground.  This rental is typically the same cost as a lift gate.  As a final option, a roll back tow truck can meet the carrier and move the crate onto their bed and then lower it to the ground.  This is typically economical and most roll back drivers are trained in this process.

Once the crate is in the shop, equipment must be available to remove the equipment from the crate.  This will require people or a fork truck.  Smaller machinery can often be lifted with a few people but anything like an embroidery machine or an automatic press will require a fork truck to place the machine into position.

If it is being delivered by the manufacturer or distributor.

Typically, a driver for a manufacturer or distributor will have a plan for getting machinery to the ground and often a plan for placing it into position.  However, that installer will need people to help.  One person cannot move machinery without additional muscle.

What should be ready at your location?

An installers time is limited, so to get the best use of that time the shop should be completely ready for the product to install.  This means that in addition to having a way to move the machinery from the truck to the shop floor, there needs to be a path large enough for this to happen.  This could required a ramp up some stairs.  It could require a door removed or widened.  It could require that other machinery in the shop be shut down and moved temporarily.  All of this need to be accomplished before the truck arrives.

The next item on the list is the arranging of services and utilities.  If this machine requires water, air, electricity or gas, or a drain then then need to be set in advance.  New ovens, compressors and automatic presses require high voltage and amperage to operate so have those lines available in advance.  Compressor air lines should be run before machinery is placed and if the compressor is the new addition, check to see how water will be released from it during maintenance.

Training is a thing that takes concentration.

If the installer is also the trainer, then the staff needs to be prepared to stop production and pay attention.  This will reduce issues in the long term and make everything smoother.  If the machine is a set up and go, then your staff will still need time to experiment with setting that are best for you production.  Exposure times are calculated differently for every shop and emulsion and only recommendations can be offered from the manufacturer.  Curing times and temperatures change in each shop, so be prepared to adjust setting and check every job.  Set up for manual and auto presses is different with every press.  So learning this will take time.

If you are expecting a new printer or embroidery system, you should have artwork prepared for testing.  We do not recommend single color jobs as these do not offer enough challenges to learn the process.  But we do not recommend a high end job that you have never printed before.  Learning a new machine and a new process at the same time will cause frustration and additional down time.  So solid 3 to 4 color work is best.

Also, do not hold jobs in house waiting for machinery to arrive.  Learning a new process with a deadline looming is stressful and leads to trouble.  If you have jobs in house that this equipment was purchased for, then either send it out for now or print it how you would have before.  Yes, we understand that quick ROI is the hope, but frustration of learning is not going to help.  Keep the stress down anyway possible.

This is exciting, right?

Yes, it is.  New business and learning new skills is always exciting.  Set yourself up for smooth transitions and take breath.  Remember the steps.  Be prepared for the truck.  Be prepared with utilities and services.  Be prepared to learn.  Don't overload your shop with production delivery dates on new stuff.  And have some fun with your new toys.

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.

Have you greased me today?

ElectraPrint Stealth Series control panel

This little welcome message reminds customers that maintenance on all machinery is necessary.  The more moving parts on a machine, the higher the maintenance level.  The question for each shop is, "Do I need a technician or can we do this ourselves?"

Most maintenance is simple cleaning, lubrication or plug and play parts.  So, to answer that question, you can definitely do it in-house.  Higher end machine calibration can often be done in-house if the person charged with the task is patient, detailed and uninterrupted.  The information to calibrate all of the Brown machines can be found in the manuals that were provided originally and much of it is located on our YouTube page or on the video tab within our web site of the particular machine model.

You're not asking the right question.

The real question is not, should we do it in-house, but do we want to?  And how much does it cost to have someone else do it?

There is some simple math to figure this out.

The price above makes it appear that doing it in house is always the best way.  However, let's consider a few things.

• If the production staff is doing maintenance on one machine, is anything else being produced.
• Is that staff capable of adjusting a machine into its best working condition or just mess with it for a few hours and call it good.
• Can your shop wait for a scheduled visit or are repairs necessary at this moment.  
• Is that staff member trained to work with the tools necessary.

A trained technician can accomplish quite a few things in a short amount of time. What a trained technician cannot do is guarantee that a machine will not malfunction during your busy times.  Just like your car, they can do the 60,000 mile check up but you could still blow a tire.

• Recalibrate a press for registration.
• Replace and repair electronics in ovens and automatic presses
• Update software on certain products
• Change filters, lubricate and adjust all mechanical operations.

The decision is a matter of perceived value.  Some would say that if the printer is okay printing on what they have, then in-house is fine.  Others would want a tech to keep everything as close to original spec as possible.  Both options have value and good reasoning.

Generally, manual presses and small ovens do not justify the expense of a tech unless they are already in the building working on something else.  Once the machine has a higher level of mechanized parts, a technician every few years is a good investment.  As an example, for an automatic printer:

8 hours time (includes travel) = $1200

Every 3 years $1200/3 = $400 per year

Machine life 12 years so 4 x $400 = $1600 for the life of the machine

In our thinking, $1600 is an excellent investment in a press that is a mainstay of your production.  And, once you have invested in the travel time, have the tech work on the small stuff too.

One final note, the true question for older machinery is whether maintenance or repair still has value or should you trade up?  That question is an additional conversation in cost analysis.  Next time....

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.