Page 1

Halftone Perfection Checklist

Mark A. Coudray
Member Academy of Screen Printing Technology

Art, File Preparation, & Resolution Parameters

❑ Avoid gradations that fade to White

❑ Avoid very soft pastel grays and beiges

❑ Avoid memory or reference colors

❑ File in RGB format

❑ Color Space Adobe RGB or Apple RGB

❑ File Type .tif, .psd, .eps NOT .jpg or JPEG

❑ Review image for corruption (jpg) and get new file from customer
if necessary. JPG saved as .tif or .PSD still contains JPG damage.

❑ File Resolution 200 - 250 ppi at final size

❑ Examine file for printed halftone dots

❑ Use descreening software or >filter>Blur in Photoshop to eliminate

previous halftone patterns (if present)

❑ Merge visible layers into one layer. Keep background layer separate.

Copyright 2003 Mark Coudray • All rights reserved • Unauthorized duplication is unlawful
Halftone Perfection Checklist Page 2

Separation Settings

❑ Check all incoming files to make sure they are in RGB colorspace.

❑ If customer supplied CMYK file, you must convert back to RGB using

>Image>Mode>RGB, then reconvert to CMYK using textile settings.

❑ Use CMYK Settings for Textile Screen Printing.

❑ Load Custom Ink Color Settings.

❑ If color settings are unavailable, use SWOP Uncoated.

❑ Set GCR

❑ Set Black Generation

❑ Set Dot Gain (see Day 3)

❑ Set Total Ink Limit

❑ Gray: Gamma 2.2

❑ Spot Color: 38% (or higher up to 50%)

Copyright 2003 Mark Coudray • All rights reserved • Unauthorized duplication is unlawful
Halftone Perfection Checklist Page 3

Dot Gain

❑ Set Dot Gain in Photoshop: >Edit>Color Preferences>CMYK>Dot Gain

Standard or Dot Gain Custom>Curves. Set 88% in the 50% space. This
adds 38% to the 50% dot.

❑ Set Spot Color Dot Gain: >Edit>Color Settings>Spot>Custom or

>Edit>Color Settings>Spot Color>Curves

❑ NEVER Dot Gain less than 35%.

Film Positives

❑ Output resolution of 600 dpi or higher (preferably 1200 - 2400 dpi.)

❑ Elliptical Halftone Dot for dot shape

❑ 55 lpi for halftone resolution for Automatic Press 45 lpi for halftone
resolution for Manual Press

❑ Avoid laser toner / vellum for halftone positives

❑ Use Thermal, Ink jet, or silver-based imagesetter film.

❑ Minimum Dmax density of 3.0.

❑ Halftone dot examined under 50X magnification to make sure edge is

sharp and hard.

Copyright 2003 Mark Coudray • All rights reserved • Unauthorized duplication is unlawful
Halftone Perfection Checklist Page 4

Screens

❑ 305, 34 micron, Plain Weave (305.34 PW) mesh

❑ Yellow, Gold, or Orange colored mesh to reduce light scatter.

❑ Make sure tension is above 20 N/cm.

❑ Tension should be ± 2 N/cm within the screen.

❑ Tension should be ±2 N/cm between each screen.

❑ Seasoned retensionable frames. Mesh should have several jobs run on it

before you go to halftone images.

❑ Screens degreased immediately before coating with emulsion.

❑ High solids dual cure photopolymer / diazo emulsion.

❑ Screens coated 2X print side, 2-3X squeegee side.

❑ Use rounded (1mm) edge scoop coater.

❑ Dried print side down.

❑ Coating room temperature below 85° F (29° C).

❑ Coating room humidity (RH) between 40% - 60%.

❑ Coating room high volume filtered air circulation.

❑ Screens dried in subdued yellow safe light.

❑ Expose dried screens within 24 hours of coating for best results.

❑ Exposure calculator and light integrator used to control exposure.

❑ Test halftone areas included on the film positive to assure proper

exposure.

❑ Exposed screen wetted both sides with warm water one minute before
washout.

Copyright 2003 Mark Coudray • All rights reserved • Unauthorized duplication is unlawful
Halftone Perfection Checklist Page 5

❑ Direct forceful water spray from the print side.

❑ Washed screen free from any "sliminess" on the squeegee side after
exposure.

❑ After washout, blot inside and outside of screen with unprinted newsprint.

❑ Screen is underexposed if newsprint picks up emulsion color.

❑ Blockout within 1/8" (3mm) of the image.

❑ Avoid taping closer than 1/8" (3mm) of the image.

Copyright 2003 Mark Coudray • All rights reserved • Unauthorized duplication is unlawful
Halftone Perfection Checklist Page 6

On Press

❑ Print sequence: UB White, HL White, Flash (optional on white shirts,)

Colors - Light to Dark, Flash before Black.

❑ Always use a HL White on White shirts. This helps to control dot gain in
the quarter tone area and preserve pastel colors.

❑ On White garments, HL White can print at the front or the back of the
print sequence. Experiment to determine your best results.

❑ Use 70/90/70 triple durometer squeegees or 70 - 75 durometer

squeegees with fiberglass insert.

❑ Squeegees sharpened EVERY time before printing.

❑ Sharp blade means you can feel your fingerprint ridges.

❑ Use a balanced set of process color inks of the same ink brand. Do not
mix ink brands and colors vary and you will not be able to achieve correct
color balance on press.

❑ Use no more than 1/ 16 " off contact (1.5 mm.)

❑ If inks hang up in the screen, use a SMALL amount of curable reducer. A

better solution would be to use Halftone Extender Base. This will keep the
image looking sharp and minimize dot gain.

❑ Warm press with flashes ON until ink reads 90° F (32° C) with a non-
contact pyrometer.

❑ Flood pressure backed out until a thin, even film is visible after the stroke.

❑ Squeegee pressure backed out until there is no print. Increase pressure

until print appears, then add 1/2 to 1 turn more.

❑ Very slight deflection in squeegee blade, it should NOT be bent over.

❑ Print speed at 20"/sec (50cm/sec.) As the ink warms, increase speed.

Copyright 2003 Mark Coudray • All rights reserved • Unauthorized duplication is unlawful
Halftone Perfection Checklist Page 7

❑ No ink coating on the inside of the screen after the print stroke. Wiping
your finger over the print area should be ink free. Ink on your finger
indicates either a dull squeegee or excessive squeegee pressure.

❑ Evaluate completed print. Adust pressure up or down to balance color and

ink penetration into the garment.

❑ Correct penetration results in continuous ink film when garment is

stretched.

❑ Present 3 sample prints to the client for approval.

❑ Discuss in advance unstable areas that may be difficult to control or may

shift in color during the run.

❑ When print has been approved have the client sign all three garments with
a Sharpie Marker. The client keeps one and you keep two.

❑ Approved control positioned at the unload press station for comparison.

❑ Second signed sample positioned at the end of the dryer for print
comparison.

❑ High light level over the dryer and press so you can see the print.

❑ Lighting should be 5000°K with Color Rendering Index (CRI) of 90 or

higher.

Copyright 2003 Mark Coudray • All rights reserved • Unauthorized duplication is unlawful
Halftone Perfection Checklist Page 8

Post Production

❑ Fill out a complete Print Spec Sheet with all technical specs.

❑ Temperature and humidity at the time the job was run.

❑ Names of the operators and inspectors.

❑ Sample from the run in the final job jacket.

❑ Small sample of cured ink from each screen on the spec sheet to verify
the exact colors you used.

❑ Client follow-up one week after job delivery to make sure everything
went as planned and there were no problems you have not heard about.

❑ Ask the client if there was anything they would change about the run in
the future.

With 30 years in the business, Mark Coudray owns two companies: Coudray
Graphic Technologies, a digital color-separation, software, and e-business
firm specializing in electronic prepress for the screen printing industry, and
Coudray Serigraphics, a screen printing operation. He has served as
Chairman of the Screen Printing and Graphic Imaging Association (SGIA)
and the Academy of Screen Printing Technology. He is the recipient of the
SGIA Parmele Award, 2 Swormstedt Awards, and the Magnus Award. He is
a frequent contributor to the industry trade press and is a sought after speak-
er and consultant. Contact him at 825 Capitolio Way, San Luis Obispo, Calif.
93401; (805) 541-1521; or e-mail coudray@coudray.com.

Copyright 2003 Mark Coudray • All rights reserved • Unauthorized duplication is unlawful