Digital Garment Printing

A brief on digital printing solution in garment industry

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Printing in Garment Industry

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Methods of Printing

 There are major three methods presently used to impress coloured patterns on fabric:
• Block printing –
‐ Hand Block printing
‐ Perrotine printing
• Screen printing –
‐ Flat-bed Screen / Chest printing
‐ Rotary Screen printing
• Digital printing –
‐ Sublimation / Heat transfer printing
‐ DTG – Direct to garment printing

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Types of Screen Printing

Flat-bed screen printing m/c Rotary screen printing m/c

Chest screen printing m/c

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Types of Digital Garment Printing

DTG- Direct to garment printing Sublimation / Heat transfer printing

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Digital Garment Printing

 Sublimation / Heat transfer printing –

• The sublimation process uses an inkjet printer equipped with sublimation dyes to print an image onto sublimation transfer paper.
• The printed transfer paper is then applied to the blank substrate using a heat press.
• The cost to make a single transfer can range from $0.50 to $2.50 depending on what ink and paper is used by your printer.

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Digital Garment Printing

 DTG – Direct to garment printing –

• A DTG printer uses a horizontally moving inkjet print head to apply an image directly onto the surface of a garment, which is
mounted on a platen that gradually feeds the garment through the machine directly below the print head.
• Special, quick-drying inks designed specifically for the fabric being printed — typically 100% cotton — are used in the process.
• DTG printing involves the use of a highly modified inkjet printer with specially formulated, water-based garment inks which are
heat set with a heat press or tunnel dryer.
• Unlike screen-printing, DTG output does not require separations, films and screens.
• The cost of output onto a white or light colored garment is typically under 20 cents for an 8½ x 11 image and output onto a dark
garment for the same size image is generally around $2.00.
• Production times on a DTG print are similar to those for a sublimation or thermal transfer, and generally a bit slower than those
for traditional screen-printing (once the press is set up and printing).

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Digital Garment Printing - Process

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Detail Analysis of Digital Printing

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Keys to DTG

 Many small screen-printing shops will sacrifice margins for small-run jobs to accommodate the demand of the custom-shirt-buying
public. Consistent large-volume jobs are hard to acquire and maintain due to the competition among screen printers. A small shop
may need a 12-piece job just to stay busy. This is where DTG printing stands out.

 Ideal for low-volume jobs because setup and breakdown is negligible compared to screen printing, DTG printing is slower but
preparation is faster. A conservative estimate for screen printing 12 shirts — a five-color job, from setup to breakdown — is four-plus
hours. With DTG, 12 shirts can be prepped, printed and cured in about 30 minutes.

 Think about your customers’ requests. What is the average size of the print jobs you receive? Do they want 144-plus shirts, or do they
want a dozen shirts for a party or team? With DTG, you can confidently advertise low-minimum, custom, full-color prints on light and
dark garments. Better yet, you can advertise no minimums.

 The industry is trending toward low-volume customization because the market is demanding it. DTG printing gives you a distinct
advantage in fulfilling this need. It also can be a standalone business in which you print low-volume jobs in-house and contract out
larger runs to screen printers. The DTG process also can be added to an existing print shop, as even larger shops are seeing the need
for quick-turn, low-volume orders. It’s common for shops to have multiple DTG units, with each machine printing 100 different
custom orders per day.

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DTG vs. Screen Printing

 Which embellishment process makes the most sense for your business?

 If you’ve been shopping for screen-printing equipment, you may have noticed most major resellers and manufacturers now also offer
direct-to-garment (DTG) printers. That’s because DTG is becoming increasingly popular and viable as technology evolves.

 Deciding whether to invest in screen printing or DTG printing requires examining the differences between both applications, which
have distinct sets of pros and cons. Understanding the production details of each and determining how these applications will benefit
your business is important.

 Screen printing has dominated the garment-decoration industry for more than 100 years. With advancements in ink, photo-sensitive
emulsion and equipment, the process is reliable and repeatable, and can be done by small or large shops.

 Historically, most printed apparel likely was screen printed, and most shops that considered expanding production volume looked to
that technology to help them grow. This model is changing as digital-application technologies and the market evolve.

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Benefits of Screen Printing

 The screen-printing process has several benefits, but what separates it from DTG is speed and volume. With an automatic screen-
printing press, for example, a shirt can be printed and put on a dryer belt every three to five seconds if prepress requirements have
been met. That is the major distinction between screen printing and DTG — speed and volume vs. setup and breakdown.

 It’s important to consider what you intend to accomplish and what you are willing to invest financially. To print three to five shirts per
second, you must make a serious investment in equipment, training and space. This requires automatic presses, large conveyor
dryers, an ink-mixing station and a large screen-processing and cleaning area. A full-scale automatic shop easily can cost $500,000 or
more in equipment and supplies. Typically, existing shops grow into this type of setup and gear up as production demands increase.

 Most startup or small print shops begin with a bare-bones screen-printing configuration and can be productive with much less of an
investment. A new manual press, flash unit, small conveyor dryer and a small screen-prep area can be effective. A reasonable
expectation for a new small-shop, manual-screen-print setup is $15,000-$20,000.

 Regardless of whether it’s a small or large shop, prepress, setup, breakdown and the learning curve make screen printing a difficult
application to adopt. Here is a simple list of steps involved in the traditional screen-printing process: Prepare and separate art, create
film positives, clean and dry screens, coat screens with emulsion and dry, expose screens, wash, dry, block out, dry, tape off, set
screens on press, mix ink, register, test print, print, remove screens, remove ink, and wash and reclaim screens.

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Benefits of Screen Printing

 The entire process can take hours and is sensitive to errors. If exposure time isn’t correct, a screen may not wash out. If the platen
gets too hot, the ink can stick to the bottom of the screens and cause ghosting. If you use the wrong ink or emulsion, or a screen
breaks, you must reshoot and re-register new screens. One skewed element can jeopardize an entire job.

 Though the screen-printing preparation process takes time — the more colors in the design, the longer it takes — you can start
cranking out shirts as soon as setup is done. That’s why screen printing is conducive to large-volume runs.

 Such jobs enable screen printers to make money. Prepress, setup and breakdown processes require time and resources, and these
costs must be amortized into the volume of shirts produced to sustain a reasonable margin. Large volumes fuel screen-printing shops
and can be lucrative.

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Screen-Printing Truth Serum

 Screen printing has a few distinct elements you should consider before investing in the process. It’s important to be realistic with your
expectations.

 High-quality screen printing is a complex art form, and takes a tremendous amount of money and time to master. Simple applications
are relatively easy to accomplish, but high-end, high-volume jobs can be difficult for a novice. Screen printing also requires a steady
stream of supplies to keep up with materials usage; you may invest hundreds or thousands of dollars a month to keep your shop
supplied.

 Often overlooked is the fact that screen printing is messy. Ink gets everywhere and requires constant cleaning. The screen-cleaning
and reclaiming process is a monstrous challenge. Have you ever seen the television show “Dirty Jobs” with Mike Roe? He has filmed
an episode on reclaiming screens. Trust me — it’s dirty.

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DTG vs. Dye Sublimation

 Both methods use inkjet print heads to produce a printed image or graphic. In the case of DTG, the printer is either built from the
ground up for the specific purpose of surface printing, or is created by modifying an existing printer system.

 With sublimation, off-the-shelf, office-style printers are used for desktop printing (up to about 13″ x 19″ fields) and professional
printers are used for larger formats. It should be noted that no modifications are made to printers used for sublimation, and they are
used right out of the box.

 Inkjet print systems create image color by mixing base colors that are formulated incorporating recipes created by the graphics
software. Unlike screen printing and embroidery, which use pre-colored decoration materials (ink and thread), digital printing allows
you to create thousands of custom color combinations without being limited by print stations or needles.

 Sublimation printers come in four-, six- and eight-color models, which refers to the number of base colors available for mixing, not
the number of colors that can be output. More base colors enable the creation of more precise color detail, such as realistic facial
skin tones when dealing with photographs.

 DTG printers are four-color units, and those capabilities are fine for most graphical applications — especially apparel.

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DTG vs. Dye Sublimation

 Another key point with digital printing is that the inks and dyes will only bond with the surfaces for which they were created. DTG is
primarily a cotton application, while sublimation is limited to polyester.

 Both will work on blended fabrics, but the colors may appear faded, muted or washed out. With all digital printing, there is a
challenge to deliver consistent color results on the final product. Both DTG and sublimation processes rely on digital artwork created
with standard software programs such as CorelDRAW, or Adobe Photoshop and Illustrator.

 But it takes a further level of enhancement to properly deliver accurate color output at the print head. DTG relies on raster image
processor (RIP) programs that may not be included in the initial equipment purchase. Sublimation systems rely on custom printer
drivers, color palettes and profiles that usually are provided by the manufacturer.

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 Role of Inks in Digital Garment Printing

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Use of White Ink

 There are challenges to printing on colored garments, especially dark ones. In DTG printing, one solution is to use a chemically
engineered ink called, quite simply, “white ink.”
 White ink has two purposes in garment printing. It can be used as a base coat for images on colored garments and it can be used in
the re-creation of the color white on colored garments.

 Digital colors are created by combining different percentages of base colors (mixing). Unfortunately, the color white cannot be
produced through any combination of colors; thus, white ink has to be engineered as a separate, stand-alone ink.

 Because there is not a recipe for the color white, graphics programs typically leave any white areas in a design “open” under the
assumption that they will be applied to a white surface. In that situation, the background color fills in the open area and creates the
needed white. But if the same image was applied to a blue shirt, the supposed white areas would now be blue, which may not be
ideal. With a white ink system, a command is sent to the printer telling it to apply the white ink (from an independent cartridge)
when required, thus making it possible to print the color white.

 The second aspect of white ink is the creation of base coats. With digital printing, you are applying a thin coating of ink or dye —
meaning the colors of the ink will be intertwined with the colors of the fibers, which may affect the image color. To counter this
effect, you can apply a base layer of white ink, which blocks out the background color, such that the image is actually being applied to
a white background instead of directly against the color of the garment. The process sounds easy enough, but there is a lot more to
this.
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Use of White Ink

 White ink has to be thick enough to create a decent base, yet thin enough to get through the inkjet nozzle. In addition, it has to cure
quickly so that other inks can be applied on top of it without any quality issues. Chemically, it must start “drying” as soon it hits the
surface of the garment.
 This is accomplished by a two-pronged approach. The first is that the white ink itself must be engineered to cure quickly. The second
is that a secondary chemical called a pre-treatment typically is added to the surface of the shirt before printing. When the white ink
contacts the pre-treatment, the curing time is accelerated such that the production proceeds uninterrupted. This means there’s no
need to stop and wait for drying to occur.
 Early white ink systems developed a reputation for clogging and drying out in the print heads, which led to expensive repairs. New
advances in technology have greatly improved the process and — for the most part — if you fully understand how your system works
and follow the instructions provided by the manufacturer, you shouldn’t experience significant problems.

 In reality, white ink is not needed on every job; thus, not all DTG printers offer it. But before you insist on having white ink
capabilities, make sure you balance your desire against your need. White ink does present challenges, one of which is the artwork
that has to be prepared differently to accommodate white ink. So know what you are getting into, especially since it typically raises
the price tag in addition to the level of production complexity.
 What about white ink for sublimation? It’s not available. There are some alternative methods, such as allover sublimation where you
apply an image that completely covers the surface of a shirt. You start with a white shirt and then recolor it while adding graphics all
in one step (per side). It requires a wide-format printer and heat press, but is gaining in popularity for creating retail-inspired looks for
a multitude of market niches.

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Range and Cost

 Whereas DTG has the advantage over sublimation in terms of printing on colored surfaces, sublimation takes the cake when it comes
to the range of products that can be decorated. Sublimation-ready merchandise includes plaques, awards, promotional products,
photo panels, memorial products, signage, mugs, flip-flops, koozies, flags, tiles, iPhone covers, laptop sleeves, stadium seats, acrylics,
pet products, etc. One machine can decorate hundreds of products!

 Moving on to costs, both systems are close in terms of production numbers with a large, full-color image averaging about $1 in media
costs. But in terms of startup costs, there are significant differences between the two. DTG printer costs start at about $16,000 and
increase from there. In contrast, an entry-level desktop sublimation system starts at about $575 (without a heat press) and tops out
around $2,500.

 Is one system better than the other? It really comes down to your needs. Take the time to calculate the ROI for each — which goes
well beyond equipment costs — as you also want to take versatility into consideration. Which process will give you the widest range
of decoration services and product options based on the needs of your business? The answer to that question will generate the most
business in the long run. Be diverse, creative and — most importantly — profitable!

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Buying a Garment Printer that prints white ink, Pros and Cons

 Pros and Cons of Printing Dark Shirts

 So, you’ve decided to add a direct to garment printer to your existing apparel decoration business or even to start a business based
on direct to garment printing. One of the first things to consider is the marketplace you will be selling to – simple example – are you
selling to motorcycle clubs that require Harley Davidson style shirts?
 If so, no doubt you will be printing a lot of black shirts – white ink is a necessity. Unfortunately, not all situations are that cut and
dried.

 When you are considering whether your garment printer should have the ability to print on dark garments you should know and
weigh the pros and cons. Why is this so important?
 Some printers, like the Brother GT 541 Digital Garment Printer, the Mimaki garment printer and the Sawgrass Direct Advantage
printer do not offer a white ink solution at this time. Other printers, like the DTG line of t-shirt printing machines, the Fast T-Jet
machines by US Screen Printing and the Flexi-Jet garment ink jet printer offer white ink either as standard or an option.
 By determining whether white ink is necessary for your business up front, you can quickly narrow your choices and save time
researching printers that do not fit your needs. Surveys of t-shirt blank distributors confirm that a full 70% of the t-shirts they sell for
decoration are NOT white.

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Buying a Garment Printer that prints white ink, Pros and Cons

 What exactly are the pros and cons of using digital t-shirt printers with white ink? Let’s look at the cons first:
 Printing with white ink costs more
• True – you will generally spend as little as 20-25 cents to print a white shirt and $2 or more to print the same image on a dark
shirt
• just as in any other type t-shirt printing or decoration – the more it costs to produce, the more you need to charge
• False – for short run jobs, the added ink costs far outweigh the costs of separations, films, screens, and setup associated with
traditional screen printing
 Printing with white ink is not as fast as printing a light shirt
• True – when compared to printing the same image on a light colored garment with no white ink, when you have to print 2 layers
as opposed to one it stands to reason that it will take longer
• False – when compared with the time associated with traditional screen printing setup – short run orders done with a digital t-
shirt printer can seem amazingly fast
 Printing with white ink is more difficult than printing white shirts
• True – as above, when compared to printing on light garments without white ink, dark garments are more difficult, that being
said, the perception of difficulty is more based on the ease of not using white in than on the difficulty of using white ink
• False – as in all methods of garment decoration, once you have learned how to properly do something, it becomes a matter of
consistent repetition

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Buying a Garment Printer that prints white ink, Pros and Cons

 Printing with white ink requires more maintenance

• True – as the white ink used in all digital garment printers has different properties than the color inks, you will need to do a bit
more maintenance than you will on a machine without white ink.
• The difference in required/recommended maintenance between a machine with white ink and one without is literally only a few
minutes a day – a small price to pay for potentially increasing your customer base by a factor of 3 to 4

 Now, let’s look at the pro’s of printing with white ink with your digital textile press
 By offering white ink printing on your dtg printer – you are equipped to handle all colors of garments your customer will request
• True - literally 70% of the imprinted t-shirts sold every year are not white and may require at least some white ink
• You can always try to “sell” your customer on using a lighter color garment that does not require white ink – the problem with
this is that you risk upsetting your client
• This is really THE reason for buying a machine with white ink – if you are not willing to give up potentially 70% of the business
that is out there and don’t want to send your customers “somewhere else” to get their dark garments printed, you need white
ink.

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Buying a Garment Printer that prints white ink, Pros and Cons

 When it comes down to it, if you feel that you can keep your digital garment printer busy full time just printing light colored garments
– then the decision should be easy.

 If, on the other hand, you are like the majority of direct to garment printer owners, you will find that there are times when the light
shirt business is not booming – then printing with white ink can be a saving grace.

 Even if you do not want to print with white ink immediately, it is a good idea to buy a direct to garment printer that will allow you to
print with white when you are ready.

 The DTG line of digital t-shirt printers can be configured to print with or without white ink and changed at any point to fit your needs.

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 Benefits of Digital Garment Printing

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Four Major Business Benefits of DTG Printing

 Profits, Profits, Profits

 It’s no surprise that customized items can cost a pretty penny. When you look at websites like cafepress.com and zazzle.com, a
custom-made T-shirt runs – on average – around $20 to $25. When you consider that the average operating cost to create a DTG print
is around $1 for light-colored textiles and around $3 for a dark color, the profit potential is incredible. Plus, the cost of the equipment
is much lower than other inkjet technologies – usually around $20,000 for a startup model and heat press. With consistent business
at a profit of at least $10-$15 for a T-shirt, you’d be able to break even quickly.

 On-Demand Capabilities
 Screen printing is less than ideal for quick, short-run orders or items that will require a lot of color variety. This is because the process
involves a good amount of upfront labor and skill to set up, execute and finish. On a one-at-a-time basis with a manual press,
someone is needed to push the ink onto the garment through a mesh screen with a squeegee or blade, and only one color can be
done at a time. Creating one or two T-shirts on short notice with screen printing is more of a pain than a profit.

 As a digital process, DTG printing requires little to no setup. This makes printing short runs quickly and on demand much easier
because there’s a lot less time-consuming manual labor involved. All you need is a digital file from the customer and you’ll be able to
print small batches of fully customized, colorful garments. This on-demand capability also enables you to charge rush fees or
additional fees for smaller orders.

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Four Major Business Benefits of DTG Printing

 High-Quality, Small-Volume Printing

 Compared to traditional screen printing, digital inkjet printing can produce a higher quality product – especially on a short run order.
Printers can fire much smaller droplets of ink, meaning the level of detail is higher and DTG printers can easily create gradients and
other types of color transitions that screen printers often struggle with.

 As a general rule of thumb, if you’re printing any more than 25 one-color items, 50 two color items and so one, it may be more
efficient to use a screen printing process. This is because screen-printing expenses are based largely on the setup process, meaning
longer print runs will reduce the cost per piece.

 Environmentally Friendly Process

 Screen printing can require inks that contain phthalates, PVC or other chemicals. Because of this, many leading DTG printer
manufacturers – like Brother and Epson – have gone the extra step to become OEKO-TEX 100 certified, which means the water-based
inks, cleaning solutions and the overall processes are environmentally safe. This gives operators the confidence of knowing that the
chemicals they are working with are safe for their customers, especially children.

 While DTG printing isn’t at the level where it can replace screen printing yet, it can still complement existing businesses. Let your
screen printer handle your long runs while a DTG printer takes care of short, on-demand jobs. Together, they can help you build and
sustain a profitable garment printing business.

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A DTG Q&A

 1. “I’m looking to produce photo-quality prints? How easily can that be done with DTG?”
• This is a popular question. Your customers probably are seeing more apparel with incredible detail and photorealistic images.
Though this is possible with screen printing, the learning curve and required resources can demand a tremendous amount of
time, money and talent. Because of their high-resolution output, DTG printers can yield the results of a normal printer. The cost
and learning curve needed to print a photo are the same as that required to print solid text.

• DTG printers operate based on the same concept as CMYK printers, so you can print any picture you see on a computer screen.
High-resolution, large-format machines can print at least 1,440 x 720 dpi. This means that if you get a photo with relatively
decent resolution — 150 dpi or greater — you can deliver an incredibly detailed result.

• Pull photos directly from a phone, computer, scanner, the internet — anywhere. It’s easy to modify, add flair and print a
professional, photorealistic image.

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A DTG Q&A

 2. “When does it make sense to screen print a job as opposed to using DTG printing, and vice versa?”
• This question highlights the importance of diversifying your production offerings. Say a customer wants 25 shirts for little
Johnny’s birthday party. The design features a five-color baseball team logo and custom text. To screen print a five-color job for
25 shirts requires art separation, five films and burned screens, washout, drying, block out, more drying, screen alignment, test
printing, printing, cleanup, breakdown and reclaiming. In short, that’s a lot of work and time for 25 shirts.
• Let’s consider the DTG process. Simply create the art on your computer, save it as a transparent-background PNG file and upload
it into the RIP software. Printing, which should be done after machine maintenance has been performed, simply requires
pretreatment, drying, printing and drying again. With the best DTG printers on the market, maintenance is easy, as are
pretreating and drying shirts. Thus, a five-color job can be printed in one to two hours. The time and cost are minimal, and the
returns are high.
• On this type of job, DTG printing makes the most sense. But let’s examine a one-color job (white ink) to be printed on 25 black
shirts. For screen printing, it’s easy to burn one screen, then print, flash, print and dry the design. Setup and breakdown times
are minimal, and white ink is inexpensive and looks good.
• On the digital side, achieving a bright white print on a black shirt requires a lot of ink, possibly making it more costly than screen
printing. Time also is a factor; you may be able to set up and screen print this job faster than having to pretreat and print using
the DTG method.
• At this point, analyze costs for both printing methods. Time and resources also should be considered when evaluating such a job.
Which method will be most profitable and least time consuming? One-color jobs are fast and easy when screen printing. For jobs
requiring two or more colors, DTG may be a more logical approach, especially when it comes to maximizing profits. After all,
you’re in business to make money. Use the process that will be easiest and generate the most profit.
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A DTG Q&A

 3. “My customers are concerned about washability. Doesn’t DTG wash out, while screen printing is more permanent?”
• The answer to this question has two parts, but is simple. First, just because a shirt is dry doesn’t mean it’s cured. Most
applications require a certain temperature and time to “set” the print. If these requirements aren’t met, it may wash out. This
can happen in screen printing and DTG. Follow the manufacturer’s guidelines, perform wash tests and set a policy that ensures
prints will be properly cured.

• Second, plastisol, water-based and discharge screen-printing inks are durable. Plastisol can crack and peel after numerous
washes, which most customers don’t like, but the problem usually is poor application. Screen-printed ink washability has set the
standard.

• DTG ink, on the other hand, has a reputation of washing out after a few launderings. However, some manufacturers guarantee
five-star washability from the American Association of Textile Chemists and Colorists (AATCC). This means a properly cured DTG
print can be as good as — if not better than — a properly cured screen-printed design.

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A DTG Q&A

 4. “Doesn’t DTG require a lot of maintenance? I don’t want to constantly be working on equipment.”
• Maintenance is a necessary element for most DTG printers because the process involves lots of sticky, water-based ink being
used and flushed. The best printers on the market feature built-in maintenance, but ink still needs to be managed. This
specifically applies to white ink; CMYK inks don’t typically cause problems.

• The issue with white ink is titanium dioxide, which is the main white pigment in nearly everything you use that is white
(toothpaste, paint, white correction fluid, etc.) Not all white DTG ink is the same. Most systems require regular white-ink flushes
to mitigate buildup and clogging. Every system requires some sort of manual cleaning of components that come into contact with
this ink.

• However, a few DTG printers require little maintenance because cleaning is automated. They can be turned off for seven or more
days at a time without fear of white ink drying and clogging the system.

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A DTG Q&A

 5. “DTG never will be able to keep up with screen printing on large orders.”
• Such a statement was true five years ago, but not today. Many shops are moving to an all-digital format by forming “banks” of
printers. This involves setting up three to five DTG printers around a forced-air conveyor dryer. A quality, fast dryer dramatically
increases production efficiency, meaning pretreated shirts can be dried and printed shirts can be cured at the same speed
without a heat press.

• The price of productivity also should be considered. For example, a 10-color, 12-station automatic screen-printing press could
cost more than $150,000. Additional equipment includes a dryer, washout booth, dark room, inks, screens, film printer or direct-
to-screen (DTS) system. Those expenses can add up quickly.

• DTG production costs are much simpler to calculate. The industry’s best printer is affordable, at $13,000-$18,000. A pretreatment
machine costs $4,000-$6,000 and a conveyor dryer costs about $15,000. In fact, you could buy two sets of five DTG printers and
one dryer for the same cost as one automatic press.

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Tips for DTG

 The ‘M’ Word - Maintenance is a major factor in DTG productivity. If you’re constantly working on your machine, you’re not printing
and making money. Do your research and invest in a printer that requires the least amount of maintenance so that you can avoid
prolonged downtime.
 DTG ink has a reputation of washing out after a few washes, but some manufacturers guarantee washability that is on par with, or
even better than, that of screen-printing ink.
 Always analyze time and costs required for screen printing a job vs. production via DTG printing. This includes time spent imaging
screens.
 To enable speedy production, many decorators set up multiple DTG printers around a conveyor dryer.

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The DTG Revolution

 To understand the impact of DTG, first you need to appreciate the importance of inkjet printing. Inkjet technology, around the turn of
the new millennium, was revolutionizing the way all kinds of products were being decorated. With quality prints, more customization
options and lower costs per print combined with a significantly more accessible equipment price point, the garment market wanted
in.

 Many of the first DTG machines were remanufactured from existing inkjet printers in order to print on T-shirts like the T-jet that was
introduced at the 2004 SGIA in Minneapolis — a retrofitted Epson photo printer using Dupont inks. Several other manufacturers
introduced DTG printers around that time, many with the ability to only print on light-colored garments.

 While the new technology was exciting, the arrival of DTG wasn’t without its setbacks. Printing on dark garments, in particular, proved
difficult and required significant attention to both the equipment and process. On top of that, early DTG printers had difficulty
producing consistently or reliably, which caused the reputation of the technology to take a hit.

 Needless to say, DTG technology wasn’t 100% there — yet.

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The DTG Revolution

 Evolving Digital Technology

 Like with many new technologies, figuring out the kinks was the first step toward developing an efficient, working product. These
initial forays into on-demand and customized garments had only begun to whet the appetite of the market.

 With printer manufacturers realizing their challenges early — limitations on dark garments, low production reliability and the market
demands — figuring out a solution was only a matter of time.

 DTG engineering has continued its trend out of basements, garages and backrooms and into the hands of the big names in the
printing industry, like Epson, Kornit, Brother and others. These manufacturers have developed full lines of DTG printers, complete
with dedicated research-and-development teams and engineers, as well as the resources and tools necessary to help this printing
method evolve to its full potential.

 The DTG Niche

 Although DTG printing is still in its early years compared to screen printing, the technology has progressed light years beyond where it
started. And DTG printing may have evolved at just the right time. The popularity of ordering small batches of garments online has
increased tremendously in the last few years, and traditional printing methods aren’t able to satisfy the demand for these orders.
Purchasing one or two customized shirts or dozens of multi-color prints is now the ideal workflow for DTG printers and they can
knock them out in no time.

35
The DTG Revolution

 DTG printing also offers other benefits, including:

• Low set-up costs
• Instant turnaround times
• No screens, films or separations required
• Minimal space required
• Less mess from handling inks
• High-quality, vibrantly colored work
• Short-run friendly
• Completely digital process
• Simple and infinite customization possibilities
 These benefits keep pricing competitive for products, which also is helping the industry thrive.

 It seems that we’ve gotten over the bumps and hurdles with DTG printing equipment, and now the quality is better and more durable
than ever before. The early years of DTG may not have been up to the task, but thanks to big-name manufacturing and engineering,
and a continued demand in the industry, this printing method is now the go-to for on-demand, short-run and full-color prints.

36
Peeking Into DTG’s Future

 1. Print Speed:
• Like other large-format printers, speeds have increased and will continue to do so. One of the arguments against DTG is that the
print speeds cannot match those of screen printing. With larger heads and multiple platens allowing decorators to load multiple
shirts, it is highly feasible that DTG will deliver screen print-like speeds one day.

 2. Color Gamut:
• We know the cyan, magenta, yellow and black (CMYK) color range is limiting, but many large-format printers have moved beyond
it. Though DTG still uses CMYK and white, expect additional colors, and even metallic ink, in the near future.

 3. Larger Print Dimensions:

• Currently, DTG printing is limited to about 16 inches wide and variable lengths. I expect the widths and platen sizes to increase in
the coming years. One advantage of a wider format is the potential to print on large fabric rolls.
• Though maybe not particularly advantageous for the custom apparel manufacturer, this is one avenue of DTG printing that has
enormous potential for the fabric industry.

37
Peeking Into DTG’s Future

 4. Pretreatment:
• Ink chemistry constantly is evolving. Some manufacturers are making running changes that advance opacity, shelf life, usability
and durability. Can white ink ever be used without pretreatment on the darkest garments? It may be possible, but it seems
unlikely. What is more likely is continued advancement in pretreatment solution and its application to garments. Pretreating in
line with printing will continue to advance and be more feasible with new changes to ink and pretreatment solution.
 5. Competition:
• An area that will significantly boost technology and advancement is the competition between major printer manufacturers. The
early days of DTG were challenging because pieces and parts were repurposed from other equipment. Some of these types of
printers still exist, but major manufacturers now are invested and completely revolutionizing the industry.

38
How to Increase Profitability by Ensuring Right Price

 DTG Pricing vs. Screen Printing

 Screen printing has many expenses the customer must absorb, including art separation, film positives, screens, setup and printing
costs. These all are related to the number of colors in a job. In addition, the more colors the printed artwork has, the higher the
expense, as more time and resources are needed.

 DTG printing is different in that there is very little — if any — setup and breakdown time, and printing — whether with one color or
the entire CMYK spectrum — is as simple as pushing a button. You don’t charge by the number of colors, which is a selling point
people often overlook.

 Rather, DTG prints should be priced by their size, which is directly related to ink consumption. When using a digital printer, ink
cartridges need to be replaced, which constitutes the bulk of the cost. The larger the print, the more ink that is consumed, and more
ink means more cost; it’s that simple.

39
How to Increase Profitability by Ensuring Right Price

 Measuring Ink Consumption

 It’s best to have a cost estimator built into your print imaging software or driver to measure ink consumption. Older methods
included weighing shirts and manually tracking consumption, which made it extremely difficult to accurately price jobs. In fact, we
often guessed.

 Figure 1 is a screen shot of the cost-estimator tool in Garment Creator. In the green box, you can see that a 600 ml ink cartridge is
$207, which equals $0.35 per ml. This tool measures volume.

 Develop a reference guide for measuring ink consumption by creating a series of solid shapes of varying sizes (Figure 2). Then, take
each grid into Garment Creator, select the print preferences and run the cost estimator.

 Print preferences include whether you will be using color ink only, white ink only or a combination of the two, as well as the amount
you want to print. Figure 3 shows a cost breakdown of a 6″ x 8″ print on a black shirt with color and white ink.

 Not all of your customers’ art will fit into these reference shapes, but you can use strategic size templates as a guide for your pricing.
The better you understand operations cost, the more informed decisions you can make.

40
How to Increase Profitability by Ensuring Right Price

 Other Costs
 It also is important to calculate maintenance and other consumables when determining DTG pricing.

 The collective maintenance cost on a printer like the Epson F2000 essentially is broken down into two portions: the replacement
parts for the print-head cleaning kit and the cost of ink waste when performing a white-ink tube flush. The print-head cleaning kit
cost is fixed — $100 for every 1,000 prints, or $0.10 per shirt. The white-ink tube flush is variable and completely dependent on time.
If you were to print about 100 shirts per week for six weeks, your cost would be about $0.20 per shirt.

 Other consumables primarily include pretreatment solution, but you also should add electricity, rent, labor, T-shirt costs and any
other overhead. I like to factor in T-shirt costs, which are variable, after I have accounted for my machine and main consumables
costs. I often mark T-shirts up about 30% more than wholesale prices.

 Remember that a DTG machine will print exactly what is on the screen. Using these solid shapes on a dark shirt, the output will be a
solid 6″ x 8″ white rectangle and solid 6″ x 8″ blue over the top. This type of design will estimate the full cost of a 6″ x 8″ print area.
Your customer’s art likely will not cover every square inch of a 6″ x 8″ print area, but it’s better to overestimate than underestimate.

41
How to Increase Profitability by Ensuring Right Price

 Pricing Guideline Theory

 DTG is significantly less labor-intensive than screen printing and can quickly produce one-off garments, and the margins can be high.
Charge a fair price, but your time and effort should be considered when setting a price chart.

 It’s best to charge a fair value for your time and expenses, and provide a discount — if needed — after the full price is quoted. Don’t
give away your services when quoting a job; sell them. Remember, DTG has a distinct advantage over other decoration techniques: It
can print one full-color, full-size image on a light or dark shirt in minutes.

 Some people think this should be inexpensive, but consider the alternative. If a customer wants a picture of little Jimmy printed on a
T-shirt for his birthday, screen printing is an option, but expenses will include art separations, films, screens, setup and printing costs.
For one shirt, my old screen-printing shop would charge a minimum of $350. The customer could opt for transfers, but they can be
thick, plastic, vinyl stickers — not ideal or necessarily cheap.

 Using little Jimmy’s shirt as an example, if the customer needs me to provide artwork, I may include a $20-per-half-hour art charge. I
also may include a one-time setup fee of $10 to cover testing and adjustments. I would then reference my chart to figure out costs for
the print size and ink consumption.

42
How to Increase Profitability by Ensuring Right Price

 Pricing Guideline Theory

 Let’s say the print is 6″ x 8″ with a $3 shirt. We know 100% markup is $10.82, but for one shirt I might charge a 200% or 300% markup
($16.23 or $21.64), then factor in the additional costs. A one-off shirt for Jimmy might look like this:

 Art per half hour: $20

 Setup: $10
 One black youth large 6″ x 8″ print: $16.23
 Total: $46.23

 This may appear expensive, but I think it’s fair and you should sell your customer on why this is a good price. However, if you want to
apply a markdown, your customer will appreciate the favor. Plus, you know the limit you can apply. Try a 10% or 20% discount as a
solution to keep all involved parties satisfied.

43
DTG Printing Machine Comparisons

44
DTG Printers Available in Markets

Anajet’ Sprint Azon’s Texpro Brrother’s GT-782 DTG Digital

Price/Unit- 8-10 Lakhs Price/Unit- 8.8 Lakhs Price/Unit- 15-21 Lakhs Price/Unit- 16-20 Lakhs
ROI – 10-12 months

M&R’s I-DOT 2100 EPSON’s F2000 Kornit’s 951 Omni Print’s Freejet 32
Price/Unit- 8-10 Lakhs Price/Unit- 12-16 Lakhs Price/Unit- 40 Lakhs to 2 Crores Price/Unit- 3.6 Lakhs
ROI – 8-10 months

45
What’s your Latest DTG equipment and how has it Been upgraded?
Anajet -
• Our latest DTG printer is the
SPRINT. In comparison with our
previous model, the FP125, it
has several enhanced
capabilities—
• key among them are speed and
lower maintenance
requirements. It can print a T-
shirt in 60 seconds or less.
46
Azon -
• The TexPro uses the A2+ print
format with low ink
consumption and comes
bundled with professional,
easy-to-use RIP software.
• Our printers use magnetic,
interchangeable tables, so
many different types of
garments can be printed on
them. We also use only one
type of ink for all garments.
Brother -
•Brother currently offers two DTG
printers—the GT-541 and the GT-782.
The Brother GT-541 allows the user to
print directly from their computer or
from a flash card. It’s as simple to
operate as a desktop printer and
consistently delivers high-resolution
print quality.
•This machine is for small- to medium-
sized shops or those who just want to
dip a toe into digital garment printing.
The Brother G-782 is for high volume
shops. Production is increased as a
result of reduced cycle times and its
ability to print multiples simultaneously.
It has extra-large dual platens, both
CMYK and white ink capability, and
eight inkjet heads.
DTG Digital-
• The DTG Viper is our latest. It
offers a large print area (16.5 x
29 in.) and a belt-feed system
that allows for an efficient
workflow in large-volume
operations.
• It also incorporates the White
Ink Management System
(WIMS), which minimizes the
settling of white ink, thereby
eliminating many clogging
issues.
What’s your Latest DTG equipment and how has it Been upgraded?
Kornit -
• The Avalanche 951 is the newest
machine. It has a twin Y axis
compared to a single Y axis on the
Storm 931. This gives it two
independent printhead arrays, one
white and one CMYK. This allows
the white ink to be printed
independently of the CMYK while
being in action simultaneously.
Print times can be cut in half
because the white print array can
print on one platen while the
CMYK prints on the opposite
platen. We doubled the number of
CMYK printheads on the Avalanche
to further increase its speed.
47
Lawson -
• The Lawson Express-Jet T2020 now
has a larger print area (20 x 20 in.)
and has interchangeable platens to
suit specific printing needs. It is
designed to be a robust, industrial-
floor model machine. Baxter: The
most recent additions are the i-Dot
4100, which prints on both light
and dark garments with equal ease
of operation, and the i-Dot 2100,
which prints only on light and
pastel garments, using a dual
CMYK ink supply for faster print
speeds. Both offer an improved,
user-friendly operator interface.
EPSON -
• The G2 Direct to Garment Printer
is the latest solution distributed by
Melco. This is a new machine, not
an upgrade. Importantly, G2 is not
a MelcoJet. The G2 stands on its
own. It can print on both light and
dark garments at speeds that help
businesses maintain profit
margins.
Omni Print -
• The FreeJet 330TX is now in its
sixth series and is equipped with
our WetCap maintenance system
designed to maintain and preserve
the printhead. It shields the
printhead from the elements and
safeguards it against clogging. It
creates an air-tight protective
enclosure for the printhead. It also
comes with an interchangeable
platen system for printing a variety
of soft goods. The FreeJet 330TX
has a four-lift system to
automatically raise and lower the
print bed, keeping it level. It has an
upgraded bed size of 13 x 22.7 in.
It has an upgraded print engine,
new firmware, and technical
upgrades for faster printing
Will most garment Screen Printers Switch to DTG?
Anajet -
• No. Most garment printers who
are running significant
production levels will add a
digital garment printer or two.
If it’s a short run, digital
garment printers are cheaper to
run by orders of magnitude.
Garment decorators who seek
to innovate and watch out for
threats will add a digital apparel
printer to their business. The
pie isn’t shrinking; it’s the most
adaptable businesses that will
thrive.
48
Azon -
• The market has a place for DTG
printers, but also for screen
printing and other methods.
Today, however, there is a
noticeable shift toward smaller
and customized print runs,
where DTG printers are the best
option.
Brother -
• Without question, that is
the direction we’re going. DTG
is faster and less expensive to
operate than traditional screen
printing machines
because there is minimal set
up, tear-down, clean-up,
screens, squeegees, or
platen adhesive. DTG printing
allows for small runs, which is a
huge benefit for custom shirt
operations ad smaller shops.
DTG Digital-
•I don’t know that I would use the word switch.
I would definitely use the word add. More
garment printers are recognizing that DTG
printing is simply another decoration tool. It’s
not going to replace traditional screen printing
for the majority of jobs, and it can actually be
used to complement screen printing by
offering an inexpensive option for reorders,
samples, and add-ons.Borucki: Because the
printers can now achieve digital output of up
to 300 prints per hour, this will make it
financially attractive to a larger share of
traditional screen printers. Landesman: Our
estimates are that within 10 years, the industry
will be 50% DTG. Screen printing is not going
away. There will remain a strong need for
screen printing as certain materials are not
easy to inkjet; furthermore, specialty inks like
glitters, foils, glowin-the-dark inks, are not
jettable at this time.
Will most garment Screen Printers Switch to DTG?
Kornit - EPSON -
• N/A • DTG printers are an enhancement
to a printing business. This printing
technology enables any apparel-
decoration or promotional product
business to enjoy profits never
before possible. Screen printers
can make a decent profit on a one-
off shirt that was out of range in
years past.
49
M&R -
• While screen printing will always
have an important role in the
garment-embellishment process,
DTG printing will have an ever-
increasing place.
Omni Print -
• DTG equipment is a great
supplement to traditional garment-
decorating methods, such as
screen printing and embroidery.
We’re witnessing an increased
combination of DTG and traditional
printing in most production lines,
and we anticipate a steady growth
in this trend. With the ability to
print full-color graphics instantly
with fast turnaround and no setup,
we definitely foresee most
garment printers using DTG
technology in their shops.
What types of ink Does your equipment use for Direct to Garment T-Shirt Printing?

Anajet - Azon - Brother - DTG Digital-

• Our printer uses two general • One set of CMYK and one set • It is a water-based ink • Copeland: It uses aqueous
types of water-based pigment of White cartridges. The ink is a developed especially by our pigmented textile inks with
inks—one that works best on water-based pigmented firm for printing on garments. binders offered in five colors—
organic fabric, AnaBright, and formulation. We have done extensive wash cyan, magenta, yellow, black,
another for synthetics called testing and have found that the and white.
PolyBright. Our white ink looks ink is durable.
fantastic on dark fabrics. We
have a closed-loop ink-delivery
process that enables precise
application while reducing the
evaporative process that leads
to ink clogging.

50
What types of ink Does your equipment use for Direct to Garment T-Shirt Printing?
Kornit -
• We are a vertical company that
develops and manufactures our
own digital CMYK and White
inks for our line of equipment.
Our ink is a pigmented water-
based ink that is the greenest
ink in the DTG market today,
being phthalate- and
formaldehyde-free.
51
Lawson -
• We have our own pigmented
water-based ink.
• Omni Print -
• The FreeJet DTG printers use
an advanced, water-based
pigmented ink formulated by
DuPont for optimum output.
M&R -
• The i-Dot uses our own i-Pak
water-based ink system, either
in cartridges or bulk feed. These
inks are PBC- and phthalate-
free, making them
environmentally friendly.
EPSON:
• One type of ink is used for
optimal quality and durability—
MelcoInk. This specialty textile
ink is engineered to work
smoothly with our DTG printer
and MelcoRIP printing software.
These inks are water-based,
environmentally friendly, clean,
and easy to apply. The ink
comes in 220-ml sealed
cartridges that keep air out and
ink in.
What’s the future for Direct-to-garment Printing?
Anajet -
• We see the future of this market
expanding at an exponential rate.
The key gap that separates the
greater garment-decoration
market from adopting digital
garment technology is converting
them from perceiving it as a threat
to embracing it as a new weapon
in a power arsenal of product
offerings. What DTG printing will
do is expand the possibilities for
creativity and agility for the larger
companies, while making rapid-
turnaround, shortrun, and million-
color print orders even more
profitable.
52
Azon -
• As technology continues to
develop, DTG printers will
continue to evolve and get
easier to use. The market will
expand as DTG printers become
more enticing.
Brother -
• IIncreased productivity and
quality. Future machines will
print a better product faster.
DTG Digital-
•The short-term future is probably more of the
same as we have now, though we will see
smaller players falling by the wayside as it
becomes harder to re-purpose the Epson
printers that the majority of DTG printers are
based on. It has been more difficult for non-
Epson-authorized developers to get parts for
their machines (most notably printheads).
Currently Impressions Technology and
Mastermind are the developers in the
marketplace with contracts with Epson to
purchase their print engines for re-purposing
into the DTG marketplace. Long-term, we will
begin to see the larger DTG manufacturers
releasing printers that are not re-purposed
Epsons, and instead have units developed on
the Ricoh heads or modifications of existing
large-format printers, much like those used by
the sign industry. We have only really started
to scratch the surface of DTG potential.
What’s the future for Direct-to-garment Printing?
Kornit -
• The best way to describe the
future for DTG is with a single
word: unlimited. We are always
developing new equipment. As
technology advances with
printheads capable of
unbelievable firing rates,
coupled with the mechanical
accuracy of the linear drives
available today, you will see an
unprecedented surge in
technology soon.
53
Lawson -
• The future is tremendous. As inkjet
printers become faster and more
agile, as systems improve, we will
continue to see dramatic growth in
this emerging market. Consumers
are more demanding and want
their products faster.
• M&R -
• We feel that the many
Advantages of DTG printing will
promote continued growth and
allow DTG printers to take an
increasingly significant role in
the industry.
Omni Print - EPSON:
• We’re looking forward to • DTG printing will continue to
largeformat DTG models, smaller- grow as consumer demand for
sized tabletop units, as well as ink- personalized and custom
technology advancements. We are
products increases. With no
witnessing a DTG shift from an
emerging to an established minimum quantity
technology, widely used and requirements and photo-quality
coupled with traditional forms of print capabilities, profit
garment decorating. With the on- potential for businesses of any
demand customer base expanding, size remains strong.
the personalization and mass-
customization market multiplying,
and traditional printers recognizing
the countless benefits of DTG
technology, we anticipate a
continued rise in DTG demand.
Digital Printing Workflow – Making the Most of Direct to Garment

54
Cost per Print

 Digital Garment Printers all have one fundamental thing in common. They all use ink.
 The amount of garment printer ink is used in printing shirts and the cost of that ink serious impact on the cost of your end product. In
a competitive market, that may mean the difference between a profitable job or not and in how you price your work in relation to the
competition.
 Cost Per Print for Green Earth T-shirt 14″ x 12″
 Based on Ink useage estimates and current publicly available Ink pricing information –
 Printed on Dark shirt NOT including shirt cost.

55
Cost per Print

 The cost of doing business is going to be the same no matter which printer you use.
• A quality blank t shirt, like the Anvil 980, is going to cost everyone about $2.37 from Sanmar.com.
• You will pay your employees the market rate in your area, and so will your competition
• Depending on where you do your production work, it’s very likely your building overhead, electricity and other ancillary costs of
doing business will be roughly the same.
• Many times your customer is bringing YOU the artwork, so while talent and creativity are important it won’t necessarily effect
the cost of your production work.
• Here is what that means to your business, if you use the M2 to print 20 shirts a day – 5 days a week – 50 weeks per year and sell
for $15

56
Cost per Print

57
Cost per Print

 Cost per print, and more clearly the cost for the INK in each print, is what makes the M Series Industrial Direct to Garment Printers
the most profitable digital printers on the market.
 Because of the cost per print using P30i garment printing ink that comes in every M2 it is less expensive to print a design on a t shirt
than Epson DTG, less than Brother DTG, less than Anajet, less than Kornit and every other brand.
 According to publically available pricing information to date, here is how significant the difference in ink costs are by liter for a few of
the competitive printers. The following percentages are how much more costly the inks are vs. Genuine DTG Inks and the Ink Savers
Pro program from ColDesi:

58
Digital Garment Printing Profits - BIG Prints = BIG Money

 The typical graphic on a custom t shirt is 10” x 12” and looks amazing on a small t shirt, good on a medium t shirt – and TINY on a
Large, XL, XXL and bigger.
 Screen Printing
• The custom t shirt business was dominated by screen printers for decades and the business evolved to take advantage of that
technology.
• Graphic size variations in an order for 100 shirts – one size for small, one for medium and one for large, this example, would cost
3 times the money to set up in both time and materials. So a screen printer would pick a standard size and the customer would
never know there are options.
• A 4 color job means that you need to make 4 screens. Those screens have a fixed size image on them, so you if you want to offer
2 sizes you now need 8 screens – 3 sizes? Now it’s 12 screens.
• That is just not a profitable scenario for a screen printer.
 Most Digital Printing
• Every piece of equipment and basic technology has its pros and cons. If you have a screen printing system you maximize your
profits one way, sublimation, another way. Direct to garment printers are not all made alike and that equipment difference is
revealed in graphic sizes offered as well.
• The Epson, Brother, Anajet and indeed almost every DTG Printer on the market comes able to print graphics up to 14” x 16”, one
at a time. So, can you guess what the maximum size print they’ll offer a customer is? In each of these products you can purchase
an additional platen that will allow up to almost a 16’’ x 20” print – but few companies do.

59
Digital Garment Printing Profits - BIG Prints = BIG Money

 They do not purchase the larger platen and try to print bigger graphics for several reasons:
• They use a fixed platen. That means if they want to go from printing a 12” x 10” print to a 16” x 20 inch print they have to
unscrew the platen that’s on the machine and screw in the bigger one.
• It doesn’t fit the screen printing model their business is following – offering one size fits all.
• Cost of ink rises in relationship to the size of the graphic and their cost per print just gets too high.
• They don’t HAVE to. Since so few companies offer proportional printing and can accommodate XL and up sizes there’s little
competitive pressure to force them to offer bigger prints

 Transfer Printing
• Just a note about printing transfers and sublimation – both are usually limited to the size of the paper their printer can handle.
That caps their size offering to 11″ X 17” (actually about 10″ x 16″) so bigger sizes are not even an option.

60
Digital Garment Printing Profits - BIG Prints = BIG Money

 How do BIG Prints = BIG Profit?

• The level of flexibility offered by the capabilities of the M series for
print size and the and lower cost per print help your business win
more profits in 2 ways:

 Exclusivity – you will likely be the ONLY custom apparel business in

your market area or niche that offers great looking prints on larger
sized garments. Exclusivity means that you’ll win more new business by
offering those sizes AND will maintain business because your one of
the few people offering that particular product. Exclusivity =
Profitability.
 Up Charges – Just because you CAN print larger doesn’t mean you
have to. Show your customers an option of the standard size. Show
them what it looks like on a Medium shirt. Show them what it looks
like on a Large or XL shirt. THEN show them what that BIG graphic
looks like on an XL or bigger shirt. Price the bigger one accordingly so if
they do choose to enlarge the graphics, your profits get exponentially
bigger too!

61
Choosing a Direct to Garment Printer

62
Choosing a Direct to Garment Printer

 Basically there are two general categories of these type printers:

1. Printers based on existing printer engines (usually Epson)
2. Printers built from the ground up using existing print head technologies

 The first category can be broken into two sub-categories

• Printers based on existing printer engines (usually Epson)
‐ Machines that are basically desktop printers modified to print on a flatbed –
‐ The other sub-category would be modified desktop (or larger) printers that were specifically built to print onto garments –
 The second category of machines also falls into two sub-categories:
• Printers built from the ground up using existing print head technologies
‐ The first sub-category would be two specific lines of machine –
‐ The second sub-category would be the Mimaki line of direct to garment printers.

63
Choosing a Direct to Garment Printer

 Printers based on existing printer engines (usually Epson)

• Machines that are basically desktop printers modified to print on a flatbed –
‐ often times these machines were developed for printing on rigid goods like tile, acrylic and the like, usually with solvent
based inks or for standard water based inks with the use of pre and post treatments. The first generation of direct to
garment printers was, for the most part, this type of printer.
‐ The primary example would be the Original Fast T-Jet & Fast T-Jet II – which was based on an existing flatbed, rigid goods
printer with a bulk ink system and digital textile inks plus the addition of boards to handle garments. Second generation of
these machines were modified by the manufacturer to address some of the garment specific concerns such as garment
height checking sensors, on-board bulk ink systems, auxiliary ink pumps, and the like – i.e. – DTG Kiosk. A fair number of the
newer entries into the marketplace (especially units from China and Korea) still fall into this category.

• The other sub-category would be modified desktop (or larger) printers that were specifically built to print onto garments –
‐ examples DTG HM-1, HM-1C, Fast T-Jet Blazer, Flexi-Jet, DTG Viper. These machines incorporate features that were designed
to address the challenges of printing on garments. Features include systems to better manage white ink, extended print
areas, automated head cleanings, pressurized ink systems and ink mist evacuation systems.
‐ These machines, while still re-purposed printers where engineered specifically to print on garments and generally addressed
the shortcomings of the first & second generation machines.

64
Choosing a Direct to Garment Printer

 Printers built from the ground up using existing print head technologies
• The first sub-category would be two specific lines of machine –
‐ the Brother GT 541 and the Kornit line of direct to garment printers. These machines were generally engineered from the
ground up using more industrial duty print heads and proprietary printing technology. The generally produce higher
volumes of garments than the re-purposed printers, but at a price. With the more industrial print heads comes a drop in
typical print resolution which can effect overall print quality.
‐ Also, print quality aside, these machines come at a premium – either a high price tag (Kornits sell for $90,000-$212,000) or
high consumable costs (the Brother inks sell for nearly trip the price of other direct to garment inks. Lastly, because of their
proprietary nature – parts and service are generally much higher.

• The second sub-category would be the Mimaki line of direct to garment printers.
‐ Though not a major player in the marketplace, they do represent another type of direct to garment printer. These machines
use the more common (Epson) print heads with proprietary electronics.
‐ While this machine has not made a substantial impact on the marketplace, it is a likely model for future generations of direct
to garment printers.

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 What is the price range from lowest to highest?

• As of the writing of this article, the price range of new direct to garment printers is roughly $10,000 to $212,000 – with the
majority of models falling in the $16,000 to $21,000 range.
 What questions will a salesperson ask a prospective customer as he tries to help a customer choose a machine?
• Who is your perspective customer?
• What do you anticipate as your daily volume of prints?
• Will you be using the machine to print “on-demand” or taking orders for delivery?
• Is speed or equipment cost more important to you?
• Are you planning on specializing in a certain niche – i.e. – oversize prints, beach towels, over the collar/sleeve prints, art
canvases, etc?
• How frequently will the machine be used?
 In your opinion, what are the features a decorator should look at in terms of the most important when shopping?
• Features that address the challenges of printing with textile inks and printing on garments (like white ink management systems,
head impact prevention systems, versatility of the RIP software and platen systems)
• The training and support of the distributor/dealer you are buying from
• The actual performance of the machine – basically – did the prints you saw from the machine look good and wash well.

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Choosing a Direct to Garment Printer

 How important is it to be able to print on dark shirts?

• In today’s marketplace, being able to print dark shirts at least doubles your potential customer base. However, learning how to
properly sell and price garments when printing with white ink – printing on darks increases your consumable costs as well as
increasing labor costs/time.
 Do you have any feel for what percentage of the digital printing market is being done on darks?
• At the current time, I would estimate that those who are printing white ink are probably doing, on average, 1/3 of their work on
darks. Since machines like the Brother do not print white ink and are a decent percentage of the marketplace, the actual
percentage of dark garments that are currently being printed is probably about ¼ of the marketplace.
• Those who take the time to master the art of printing in dark garments sometimes print as much as 75% darks. I would venture
to guess that 75%+ of orders that are currently turned down or shifted to transfers or screen printing are dark garments.

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References

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References

 Links of referred websites and sources –

• https://en.wikipedia.org/wiki/Textile_printing#Engraved_copperplate_printing
• https://coldesi.com/2013/07/learn-about-garment-printing-and-garment-printers/
• https://dtgprintermachine.com/
• https://dtgprintermachine.com/digital-garment-printing-profits-big-prints-big-money/
• https://www.impressionsmagazine.com/digital-decorating/sublimation/dtg-vs-dye-sublimation/
• https://www.garmentprinterink.com/Garment-Printing-Articles/what-is-digital-garment-printing.html
• https://www.garmentprinterink.com/Table/Garment-Printing-Business/Garment-Printing-Business-Articles/
• https://www.garmentprinterink.com/Garment-Printing-Articles/whats-new-in-direct-to-garment-printing.html
• https://www.garmentprinterink.com/Garment-Printing-Articles/buying-a-garment-printer-that-prints-white-ink-pros-and-
cons.html
• https://www.garmentprinterink.com/Garment-Printing-Articles/choosing-a-direct-to-garment-printer.html

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