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Automatic Screen Printing


Automatic Screen Printing is currently unmatched in commercial printing of large run orders. Most common apparels that screen printed are T-shirts, Sweatshirts, Tank Tops, Zip Hoodies, Bermuda Shorts, Jogging Pants, Bandanas, Kid's apparel, Towels and the list goes longer like that. 

AEM Textile Merchandising Automatic Screen Printing Service Details

Automatic Screen Printing is providing an unbeatable quality with unmatched price per unit on high volume orders. It is on the other hand a very complicated printing process. Achieving good quality prints require many variables to be monitored simultaneously, continously and for every each printing job. Well experienced printer mans, good equipment and supplies are mandatory if there is a good quality screen printing is desired. 

Here at AEM, with our 4 automatic carousel machines we can print up to 12 color artworks. We use state of the art latest technology equipment. All machines are under 3 years old and we do corrective maintanence to keep their perfect condition and print quality. Our production rate varies between  25.000 - 30.000 units per day. We are printing over cut fabric pieces in the production process. Two of our automatic carousels are capable of printing over sized and jumbo type prints. That means up to 80x100 (oversized)  and 80x120 cm (jumbo) prints are performed at AEM Textile Screen Printing department with highest presicion and quality. 

cut sew piece fabric screen printing
Cut sew printed T-shirt fabric. Front piece.
cut sew printed finished t-shirt
Cut sew printed T-shirt, completed product. 

As we are the apparel manufacturer ourselves, our customers can take the advantage of the the cut sew printing. With this system, cut pieces of apparel fabrics gets printed first, than completed by sewn into the final product. This means you can order full bleeding prints, cutting edge, sharp prints from side to side / top to bottom of an apparel. This process also requires less electricity and use of resources as the cut front piece is only %40 of the total T-shirt fabric for example. This allows us reduce our carbon foot print by raising the production output levels, reduced volume and weight in the transportation, reduces energy needed for curing the inks in the dryer and storing the products. Of course on some jobs we are required to print on finished apparel as the artworks dictate that. Please continue reading below for detailed information.


Automatic Screen Printing Advantages:

* Unbeatable Price Per Unit Ratio
* High Production Volume and UPH (unit per hour) (almost 1.5 x times faster printing on cut sew fabrics)
* Wide variety of ink choices (Plastisols, Water Based Inks, Discharge Inks, PVC Compliment Inks)
* Cut Piece Printing Advantages. (i.e: A completely printed t-shirt arm, top to bottom full bleeding print is possible.)  
* Special Effects such as: sims, glitters, high density print, flock print, foil prints, metallic inks, fleurescant inks. 
* All Over Printing - Up to 80 X 120 cm
* Pantone Matching
* Trigromy Prints (CMYK)
* Process Prints for up to 6 - 8 - 10 - 12 color photo images
* High Definition Photo Prints

ASP Cons:

* Not price effective for small quantity orders. 
* Higher minimums for complex jobs due to set-ups. 

Printing Sizes:

Standard Size: 30 x 40 cm
Over Sized: 40 x 60 cm
XXLarge: 50 x 70 cm
All Over: 80 x 120 cm. 

Minimum Order Quantity:

Standard Printing Locations: 500 pieces per design. 
Custom Printing Locations / All over prints: 500 pieces per design. 

* Please note: Some products / designs may have or higher minimums, please refer to the product pages to get the exact minimums or contact us.

Production Capacity:
Daily Printing Capacity: 25.000 - 35.000 Pieces.
Average Monthly Printing Capacity: 1 million pieces


Choosing screen printing inks by AEM Merchandising

You can choose from the fllowing ink products for your prints. For those who are not into different kind of printing inks, feel free to contact us with your questions.

* Water Based & Discharge Inks
* Pigment
* High Density
* Silicone 
* Raised Silicone
* Puff 
* PVC Free 
* High Density
* Foil Print
* Glitters, Sims and Shimmers applied with adhesives. 

Water Based Inks:

Water based inks do not contain PVC or phthalates and you don't need hazardous solvents to clean the screens down after they've been used - you can simply clean them with water.

water based printing example close up photo 100% Eco Friendly Water Based Printing
Multi color water based printing over T-shirts Eco Friendly Water Based High Solid Acrylic Inks used to print for the artwork.

Water based inks do not contain ozone depleting chemicals such as CFC's and HCFC's, aromatic hydrocarbons or any volatile solvents. They don't contain lead or any heavy metals. In fact, the water based inks used by AEM Merchandising do not contain any toxic chemicals at all. They've passed the Oeko-tex Class 1 standard  and are safe to use on children and baby clothes.

100% Eco friendly Water-based inks are a good choice when a “soft hand” is desirable as WB inks dye the fabric yarns itself. This plus side is often used as an argument for why water-based is preferable to plastisol because wb has way more of a soft hand than standard plastisols. On the other hand, water based prints can be ironed directly, ironing will not damage the prints.

Working with wb inks is a complex process, the ink left on the screen will dry in around 30 seconds or less, so once started the printing run, you need not to stop until the job is complete or clean the screens with water on pause to eliminate clodging. It is always harder to color match. The curing takes thrice long than standard plastisol inks. Water based prints has to be cured around 3 minutes at 165 Degrees Celsius within the conveyor dryer with air support.

Hence it's way harder to work with WB inks compared to plastisol, we always recommend our customers to go with WB inks as much as possible. Because compared to standard plastisols, WB inks have no impact on environment or our health. 



Discharge Inks: 

Discharge Inks are a kind of water based ink working with an additional discharging agent. This printing type is used on dark colored garments, to achieve the bright colors and zero hand feel that wb inks deliver.  Discharge inks simply discharge the fabric color and replaces the color with the pigment it carry. 
Here is an example of a 4 color discharge print with dark and light green, orange and yellow. No underbase, black garment, amazing pop colors, and still zero hand feel ! People without knowledge will say; "it feels like there is no printing at all! "

AEM Merchandising  4 color discharge printing on a black T-shirt close up

AEM Merchandising Turkey, 2 color discharge white and red over a black T-shirt.

AEM Merchandising single color yellow discharge over a 100% ring spun cotton black T-shirt

PVC Free Inks: 

This type of Inks are one of the most widely used ink types for all times in garment screen printing. They are easy to work with, match color and cure. The wash ability of printed garments is excellent, if cured well. Curing of Plastisol is easy, the ink film needs to reach 155 degrees Celsius doesn't have any complex curing procedure as wb inks. 

Plastisol ink creates an ink film that can be felt with the hand. The higher the opacity of the ink gets, the greater the hand feel becomes. This heavy hand is considered a disadvantage at the consumer level however, printing artworks can be managed to separate in different ways, screens can be adjusted for minimizing this ink film thickness. Espacially using higher mesh counts for photo prints, we can minimize the ink film over the garment. 

Most screen printers print on apparel using plastisol inks, which are easy to use, color match and long lasting. However, standard low cost plastisol inks contain high amounts of PVC, Azo and phthalates that are harmful to the environment and have been linked to numerous medical disorders. Plastisol inks also require the use of harmful solvents in the cleaning process of the screens and tools after the printing. Since Plastisol is a thermoplastic, it will melt if it comes in contact with anything hot enough. For that reason, plastisol prints cannot be ironed.

AEM Textile company uses high quality plastisols , containing acceptable phthalate & pvc levels. PVC compliment Plastisol inks will pass the OEKOTex Standard 100 Certificate tests. We always provide the ink type, manufacturer and contents information in our estimates. So you know what kind of ink is being used on your products. 

High quality plastisol printing by AEM Merchandising

Fluorescent Pink Color Plastisol Printed By AEM Merchandising Turkey


Printing Tests

AEM Merchandising running washing & scratch tests for every printing run coming out of our machines. The partial printed fabrics will not go to the next stage, sewing plant, until we get the satisfactory washing test results. AEM Textile only uses inks & chemicals which passes OEKO Tex Standards. In the long production runs, samples are taken 3 times a day from each machine output randomly, the samples get tested on higher temperatures and longer washing periods than we guarantee. Dry scratching, wet scratching and cracking tests are made for every each design. The dryer settings, ink types, curing periods, flash curing and all the variables are recorded for future use and for any diagnostics on errors. The products leaving our printing division only if they have passed the washing & scratching tests and visual quality of printing result. 

Thanks for reading. Please let us know if there is any questions you may have.