Ceramic Tiles

Screen printing is the most versatile decoration method for printing challenging
glazing materials onto the unique, uneven surfaces of ceramic tiles-an indispensable
technique that can cover the demanding needs of modern ceramic designers.

Overview

Introduction

Ceramic tile designs are strongly

influenced by fashion. The most
creative designs require printing
methods using a variation of Downloads
decoration materials and inks such as
ceramic powders, metal components, Leaflet: SEFAR PA 1000 (PDF 669
kb)
fine gold particles and classic glazing
materials. Complex surface imitations, Technical list: SEFAR PA 1000 (PDF
such as natural stone, leather, carpet 1608 kb)
and wood also require a printing
Leaflet: SEFAR PET 1500 (PDF 775
method which penetrates into the
kb)
uneven printing surface.
Technical list: SEFAR PET 1500
(PDF 749 kb)
Because of its versatility to provide solutions for both ink and substrate challenges,
the screen printing method has been recently rediscovered by designers and Tension values (PDF 179 kb)
decoration specialists. Screen printing is also a cost effective decoration method that
Mesh Selection Guide (PDF 675 kb)
provides competitive pricing, and is an attractive solution for short print runs.

Screen Printing Process

Ceramic tiles are decorated using both

flat screen and rotary screen
techniques. Except for decoration of

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Hinterbissaustrasse 12 Phone +41 71 898 57 00 info@sefar.com Go to product page

9410 Heiden – Switzerland Fax +41 71 898 57 21
 special pieces within the sector of
“Third Firing,” the various colors are
printed wet-in-wet with a single firing
process at the end of the decoration
line.

However, there are no limits within the

creativity of the designers-modern
printing lines can be equipped with
several different printing heads, and it
is common to find screen printing
stations in combination with laser
engraved cylinders on the same
printing line.

The screens for direct printing ceramic tiles are selected based on: type of design,
surface of the tile, mineralogical composition of the printing components, and
exclusiveness of the finished tile.

The design determines the composition of the following screen printing components:

Inks Substrates Mesh

The printing materials
are mostly water-
based inorganic
pigments, ceramic
glazes, frits, stains,
precious metals, and
soluble salts/third firing
products
Wall tiles, floor tiles,
porcelain stoneware
Mainly high modulus
polyester mesh from 8
to 40 theads/cm (20 to
103 threads/inch),
some polyamide
(nylon) mesh for very
abrasive applications,
and wire and nickel
mesh for dry powder
printing (specialties)

Mesh selection

Artwork
Special effect printing on ceramic tiles does not require high resolution artwork,
and therefore conventional films are adequate. Artwork for marble imitations,
however, does require attention; the halftone range and the line-art in
combination with the mesh count need to be carefully selected in order to avoid
moiré effects.

Automatic centering of the artwork on the screen has also become increasingly
important because it can significantly reduce printing machine set-up time. For
this reason, computer-to-screen equipment is becoming popular for direct
printed ceramic tiles.

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Hinterbissaustrasse 12 Phone +41 71 898 57 00 info@sefar.com Go to product page

9410 Heiden – Switzerland Fax +41 71 898 57 21
Frames
Both rotary frames and rigid aluminum frames are used to screen print ceramic
tiles. Rotary screens are typically 65 cm wide, and have a screen circumference
of 125 cm (a 41 cm diameter). Rigid aluminum frames can range from 40 x 35
cm up to 120 x 150 cm.

Screen preparation
Ceramic tile screens are stretched using mechanical stretching equipment.
Some particular applications call for warp and weft tension control, and require
sophisticated pneumatic clamp systems with integrated tensioning capabilities
(like SEFAR 3A clamps).

After the screen is degreased, it is coated with an emulsion that is specially

formulated for printing ceramic tiles (most emulsion manufacturers offer a
ceramic line that provides water resistance and high mechanical resistance).
Depending on the application, direct emulsions show advantages over capillary
films for printing ceramic tiles. Higher stencil quality and better reproduction can
also be obtained by using automatic coating machines.

After exposure, stencil hardening is highly recommended to help increase the

longevity of the stencil during the printing process (stencil durability is ultimately
determined by ink/paste composition).

SEFAR 3A Clamps

Mesh selection
Today, the use of polyamide mesh (SEFAR PA 1000) has been substituted by
polyester (SEFAR PET 1500). However, for particular abrasive printing jobs,
SEFAR PA 1000 mesh specifications are used to guarantee longer stencil life.

The mesh selection depends on:

> Decorating material

> Glaze or halftone printing
> Areas or fine lines
> Roughness of tile surface
> Composition of ink/paste
> 1st or 3rd firing

SEFAR PA 1000
SEFAR PET 1500

Sefar AG

Hinterbissaustrasse 12 Phone +41 71 898 57 00 info@sefar.com Go to product page

9410 Heiden – Switzerland Fax +41 71 898 57 21