Silk
screen or screen printing (technically, Serigraphy) is a
long
used process for mass producing signs and designs
economically.
Going
into this business may require a little more time (to
learn),
effort (to set up) and money (equipment and supplies)
than
some, but it is a business that could virtually explode into
something
REALLY BIG!
The
basic idea in silk screening is to create a master screen
through
which paint can form designs on a large number of
duplicates.
You
draw, trace or photograph a design and transfer it by means
of
a crude photo process to a thin, fine grain, photo sensitive
gel
coated cloth (or "silk"), which is tightly stretched over a
wood
or metal frame..
When
the gel is exposed, the part that is exposed to light
"cures"
(hardens), while the unexposed portion remains soft.
When
cured, the soft gel is simply washed away, leaving a
"negative"
image of the design. The mesh of the silk (synthetic
silk
these days) is open (like fine screen wire --hence, the name
"screen",
so that ink (paint) can pass through the unexposed
(where
the gel was washed away) portions only -- like a stencil.
The
frame holding the designed silk is placed against the object
to
be printed, ink applied and a squeegee (like the one you clean
your
windshield) pulled across to force a small amount of paint
from
the top, through the screen, onto the receiving item
(T-shirt,
coffee mug, etc.).
The
screen printed object is removed and set out to dry and the
next
object is inserted. Obviously, literally thousands of prints
can
be made from a single screen at a very economical price.
When
additional colors are desired, a separate screen must be
prepared
for each color (much like the color separation process
in
normal printing). Most screen printers have drying racks --
designed
for the size and type objects the operator does most.
For
example, if most of their jobs are real estate signs, the
racks
will be build to accommodate at least 100 18" by 24"
masonite
type signs.
If
you do not have a separate drying room, it would be wise to
have
fans to draw air across the drying signs and expel it,
perhaps
through a vent in the roof to reduce fumes.
The
silk screen frames fit into hinged holders that keep the
screens
aligned, and a jig (possibly just wood strips and clamps)
is
et up to hold the receiving objectives uniformly) -- so that
each
succeeding color gets exactly in the right place. It takes
only
a few seconds to "screen" each item, pull it out and place
it
on a drying rack.
The
biggest (and most costly) job is setting up the design or
copy
on the screens.
This
is why a job of 20 signs or posters costs almost as much as
200.
The
first sign bears the cost of setting up; the rest represent
only
the receiving item's raw cost plus a fraction of a cent for
the
paint.
Some
printers store "used" screens when they expect additional
orders
of the same signs (like real-estate signs); otherwise,
they
wash them out when the job is completed and use them again
for
the next job -- one screen will often last for years.
Usually,
customers are charged at set-up fee and a price per
item,
such as $50 set-up plus 41 apiece for 100 or less; 75 cents
for
500, etc. Since printers are not required to tell customers
when
they save a silk "master," they are free to charge a new
set-up
even if they don't have to set up the next order. This fee
is
also an incentive for the customer to order as many items as
possible
at one time.
Of
course, there are many different levels and variations of
screen
printing -- from a small, hobby operations to an "octopus"
looking
affair, where up to four different colors can be applied
in
rapid fashion, using special, fast-drying inks.
Although
it is easy to find very expensive equipment for this
business,
it is also possible to build much for your own
equipment
--for a fraction of the "store bought" versions. There
are
many books on silk screening in most libraries that can give
you
some excellent ideas if you want to build some or all of your
own
equipment.
The
total cost to set up a small silk screening studio should be
in
the neighborhood of $500 to $2,000, depending on the size of
the
operation and the amount of homemade equipment.
For
example, a light frame (for developing) can be fashioned from
six
two bulb fluorescent light fixtures in a homemade frame.
This
produces a 12 bulb developer light source for well under
$100.
Profits in this business are excellent, unless you have a
problem
spelling (hopefully, that is a joke).
You
should make at least $25 an hour for your time, and
considerably
more with efficient equipment, streamlined operating
procedures,
and good sales effort, as you take on larger and more
complex
jobs.
Screen
printing jobs include printing name tags (on plastic or
metal
holders), bumper stickers (on self-stick paper), two foot
letters
on banners (buy them blank), designs on flags or ensigns
(also
purchased blank), political posters, (paper or plastic),
street
signs (for the city) and truck signs (fleets), souvenirs,
advertising
stands -- and thousands of other possibilities.
Some
screen printers specialize in one or two phases of the art
(depending
on the market), which allows them to keep mostly one
size
of screens, holders and drying racks.
As
a screen printer, you will be able to judge which jobs in your
area
could be most economically produced by screening --all you
have
to do is show potential customers how you can save them
money
and give them a better product!
To
get started in the screen printing business, start
accumulating
your equipment, learn to operate it efficiently
(ruin
some materials), read about the art and if possible, visit
one
or more screen printing plants.
When
you are ready, know exactly what you can and cannot do (DO
NOT
experiment on your customers -- there is too much to lose)
and
seek only those that you can do well.
Note
that the types of jobs you know you can do well will grow
rapidly
as you gain experience. Start contacting businesses that
could
use your services -- show them samples and prices.
tell
them how long it will take (since you are local, this will
be
one of your strongest selling points), but be sure to deliver
when
you promise! Place ads in the local paper, and always leave
a
business card so people can call you to bid on jobs.
Some
business people make it a point not to patronize new
services
until they show they are there to stay, so make it a
point
to call back in a month or so on businesses that didn't
sound
interested the first time. This time, you can tell them
about
jobs around town that you did.
Keep
the normal business records, but especially keep a copy of
what
the customer approves to go on his order. Have the customer
review
AND INITIAL the order sheet showing exactly (spelling,
layout,
color) how the products are to appear -- ask the customer
to
please check carefully for any errors BEFORE
you run off
10,000
copies! this little extra care will save you time, money
and
many headaches.
In
this business, you have an additional option -- something you
can
do instead of commercial jobs, or in addition to, or between
jobs.
That is buying and printing your own objects for resale.
Examples
are glass mugs with the school or town emblem, ceramic
tiles
with scenes, fancy keep off the grass signs, or even
something
to hang on a small suction cup in the car (AGGIE ON
BOARD?).
If
your business has a lot of drop-in customers or you think
there
might be a market, you can also augment your "line" with
stock
signs from really large operations. They can produce "for
sale'
signs at incredibly low wholesale prices, because they buy
the
blanks "by the ton" and screen print literally tens of
thousands
at a time. That means more profit without more work --
is
that OK with you?
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