Cleanliness is the first maintenance task for every machine

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

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

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

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

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

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

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

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

The good, the bad and the ugly.

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

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

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

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

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

Ok, we think we have made the issue clear.

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

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

Innovation Center at Brother International

 

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

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

Thank you to Brother International for the opportunity.

Linx software is a solution for production management

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

But there must be something better.

Ok, sounds catchy.  But what does it do?

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

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

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

Some maintenance required

As with reading the instruction manual, scheduled maintenance is often overlooked.  We get notifications from our car dealers that things are due.  And, to be honest, who hasn't pushed that oil change a little farther out than recommended.   However, all machinery needs to be properly maintained for optimal and profitable production.  Also, keeping with the car analogy, the ones with crank windows and no AC have fewer systems that need maintaining, right.  So the higher level the machine, the more diligence is required.

Screen print machine maintenance

As an example of basic machinery, like the crank window on a car, manual screen printing presses only need to be clean.   Clean machines mean clean shirts for he end customer.  The use of spray adhesive is the biggest factor in a screen print shop.  The spray sticks to the machines, and the lint from the garments stick to the spray.  Dirt, dust and ink stick to the mess as well.  Some shops think this is "charming", like a cotton candy coating.  But, no, it's not.  The best solution, long term is to switch to platen glue that is spread on.  It lasts longer on press and it doesn't travel and stick anywhere it is not supposed to.

The spray adhesive also affects conveyor ovens.  The spray can mist into the drive system and the control panels.  Dirt on the drive train and the belt can easily be transferred to the final garments.  Spray adhesive and lint will stick to the fans of the control panel and reduce or eliminate air flow to the electrical components causing them to overheat and fail.  As the complexity of electronic components increases, the chance of overheat is higher.  This can cause drive train system failure, heat control system failure and complete machine shut down.  So, again, get rid of the spray and clean the machine.  Easy solutions to potentially big problems.

Automatic printers are higher level machines and require more maintenance.  The Brown ElectraPrint has a suggested maintenance that is listed in it's manual.  These items begin, like all others, with cleaning filters and chains.  The biggest part of this machine is the grease.  There are grease locations in each head and in the base. For air driven machines, the maintenance increases due to the air compressor equipment and the cylinders.  Check your manual for the full list and you will probably see "cleaning" at the top.

DTG auxiliary machine maintenance

BrownDigital, with the development of the Synergy and FireFly systems, is heavily involved in the DTG production market.  While this segment of the industry has different challenges, the solutions are often the same.  Additionally, these machines are higher level and required more scheduled maintenance items with more diligence.  

The FireFly is similar to conventional curing systems.  Drive train systems, fans and motors need to be kept clean.  Filter systems and belts for the exhaust scrubbers do have a maintenance schedule, just like the filters on your car.  And if these are not followed, those will fail.  These ovens cure with quartz style heating, so stocking spare bulbs in-house is a good plan to reduce down time.  These also use thermal imaging cameras and touch screen displays.  Higher level parts need additional monitoring for continued reliable production.

For pretreat systems, the complication increases.  There are a lot of moving parts, motors and filters.  Pretreat fluid is sticky and everything it touches needs to be flushed with water or replaced on a regular basis.  There are nozzles, pumps, valves and hosing that water flush cycles need to be run.  There are filter systems for the fluid and for air flow that need regular changing or cleaning.  There is a belting system that needs cleaning due to overspray.  None of this maintenance is difficult, but it is necessary and, in the case of the Synergy, can be preprogrammed to automatically run.  Also, task reminders can be set for any other maintenance item needed.

Final notes

Maintenance is often a low level priority for small businesses.  Run everything until there is an issue and then scramble until things are repaired.  For some items, that is okay.  However, like a restaurant that needs to wash everything every day, a production facility needs to be cleaned.  

Today a long standing customer stopped in for a part for a machine from the late 1980s.  Yes, the 1980s.  It was spotless.  And, since we build a similar unit today, he still runs this one.  We did laugh that he was not a profit center for us, since he never needs to buy anything but he pointed out that this is what makes his business profitable.  Isn't that what you are in this for?

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.

Award winners from SGIA 2018

BrownDigital earns Product Of The Year in 2 categories

FireFly Curing System 
U.S. Patent No. 10,011,136

FireFly™ 

What an honor.  Our patented FireFly eared the SGIA Screen Printing Drying Equipment Product of the Year.  This system is unique to the industry in its design and function.  Thermal imaging cameras monitor the temperature of the substrate and adjust the amount of energy applied to ensure perfect cure for each item. Paired with our proprietary software that connects to our Linx Control System software, this is a product designed to cure any decorated garment, whether screen or digitally printed.

Synergy Pretreat Module

Synergy™

And double the accolades.  The Synergy pretreat module earned the SGIA Pre-press (Sprayers/Dryers) Product Of The Year.  The Synergy combines with the FireFly to pretreat goods for direct to garment printing. Configured to spray two different pretreat solutions, and to mix them from concentrated form, the Synergy system is a large scale solution to a production bottle neck.  Simple to operate and easy to clean, this unit features software scheduled maintenance of the nozzle heads with built in flow sensors.  

Additionally, this system connects to our Linx Control System software to provide complete control of any product in your on-demand production floor.

See these and our full line of products at the SGIA show in Las Vegas on October 18, 19 and 20.

2017. A year of innovation.

What an amazing whirlwind of a year.  New technology and innovation moved Brown and BrownDigital into new segments of the garment decorating industry.  This addition brings new energy and enthusiasm to existing projects as well.

So what's new?

That's a big question.  Around our facility it feels like everything is new.  New curing systems, new printing technology and completely new product lines.  

Expanded Anaconda™

The Anaconda system is a flat heater that combines with a roller in an automatic printer to flatten fibers into ink to create a smoother print surface and, hence, brighter prints.  Originally, this was developed to use a 23" x 31" M3 roller frame support platform to fit into an standard automatic textile printer, like our ElectraPrint Stealth.  The excitement for the Anaconda has grown and we expanded the possible press sizes for it.  Now it can be mounted on a 21" x 24" MZX roller frame support which allows it to fit into smaller automatic presses like our ElectraPrint Junior.

The creativity of our customers as to how this product can benefit production is exciting.  We see the Anaconda applied to prints on polyester with dye migration issues, on water base or discharge inks to activate the cure and smooth out the print and on fibrous shirts for a crisper finished print.  The options are exciting.

Synergy™ pretreat system

BrownDigital moved deeper into the world of direct to garment printing.  The Synergy pretreat module system is a high production pretreated that ties directly into the FireFly™.  This unit offers more features and sprays pretreat more evenly and at higher speeds than competitive machines.  The exciting connection to the Brother GTX line of printers allows for pod style production growth with minimal labor costs.  Check out our recent blog about these pod systems.

This system also puts more information in front of the garment loader.  There is always a concern that what is pretreated is not the correct garment for the required order.  The projection system that is included with the Synergy displays an image of the shirt required and the image that is to be printed.  This gives confirmation to the operator that the are loading the correct product.  Features like this make this the leader in pretreat technology.

Linx™ Control System Integration

What is Control System Integration?  It is complete production software that ties your orders to your pretreat, digital printer and shipping software.  A barcode control system allows for inventory control and complete tracking of goods within your production facility and into shipping.  This product has quietly expanded and is running in facilities throughout the US.  BrownDigital views this as an essential component to online sales and digital printing.  This is a lead off for 2018 and it is an exciting direction for our corporate growth.

Brown Mfg and BrownDigital are looking forward to 2018.  The expansion of market areas from our existing product line and the development of new items is exciting.  Keep watching this blog for updates.  

Synergy™ pretreat module offers speed and growth

Ok, so this is what the word means but ....?

SY36x84 Synergy with FY2x36-45 FireFly

Combine the FireFly™ patented technology in curing inline with BrownDigital's new high volume pretreat module, Synergy™, and the production rates go up while the labor requirements go down.

The Synergy™  Industrial Pretreat Module is designed for high volume digital decorators and connects directly to the FireFly™ curing system, allowing for rapid evaporation of pretreat solution and a quick turn around to the digital output device.  The flow of the operation continues with reverse transport of the garment back to the original operator.  Complete multi-variate control of each garment.

Pod systems for production allow for flexibility.

Using the production flow shown, two operators can process the full operation.  One person is the pretreat loader and the final product packager.  A second person runs 4 Brother GTX machines.  High volume, low operating cost.

90-150 units per hour

Pod designs can scale for additional production.   

240-300 units per hour

450-600 units per hour 

Speed and flexibility with minimal personnel make the Synergy and FireFly combination a must have for those shops who need to step up their direct to garment volume.