Frequently Asked Questions (FAQ) will help you come out of difficulty if you are stuck in getting good results. Our aim is to help you achieve best possible printing results from your Pad Printing Machines and Supplies.

To achieve optimal print quality, you need to follow certain set of rules but there aren’t enough books / guides available to teach you,  it all comes by experience, i share my experiences of solving various issues faced while pad printing and its solutions in relation to INK, PLATE , PAD, SUBSTRATE, OTHER FACTORS, i hope this FAQ will be helpful to all Pad Printing CommunityMr. Atul Jain

Question

I have etched thick steel plates that are etched to about 35 microns and am using a closed cup pad printer. I run and print 5-10 parts that look great and then the image starts becoming washed out looking with voids. If I leave the machine for few minutes the print looks good again and then goes back to the missing pieces syndrome. I am new to pad printing and would appreciate some advice.Mr. Kunal Sampat

Answer

This is indicative of an ink viscosity problem. If your ink is drying to fast, the pad won’t be able to pick the entire image up from the etched area of the cliche’. In this case, you’d add a little thinner (or retarder if the ink is already quite thin) to the ink or remove any pauses that may be set in the printers controls, in order to slow the drying process a little.
If however, your ink is too thin it will not completely release from the pad. Then, when the pad goes to pick up the image for the next print cycle it will deposit some of the previous image back into the cliche’.
To remedy this, either slow the print cycle down putting a pause on the print side of the cycle (and maybe even one on the pickup side) or try directing some hot air at the pad after it has picked up the image to help the ink dry a little more before printing.
If this doesn’t help you may want to start with a fresh batch of ink that you know has been set to the correct viscosity.Mr. Atul Jain


A Comprehensive Troubleshooting Questions with Answers

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Too thick.
    2. Dried out.
    3. Wrong thinner.
  • Solution
    1. 1. Add thinner.
    2. Clean cliche with thinner.
    3. Use slower thinner or one suited to ink system.
  • Problem
    1. Insufficient etching depth.
    2. Wrong screen ruling.
    3. Surface physically damaged.
  • Solution
    1. Produce new cliche with greater etching depth.
    2. Test new cliche with different fineness of halftone screen.
    3. Use new cliche.
  • Problem
    1. Too flat.
    2. Surface roughened.
    3. Pad swollen.
    4. Surface too oily
  • Solution
    1. Use more tapered pad shape.
    2. Replace pad.
    3. Blow air on pad.
    4. Clean pad (several times) or replace.
  • Problem
  • Solution
  • Problem
    1. Pad is pushed onto cliche too strongly..
  • Solution
    1. Decrease head stroke of pad.
INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Too thin.
    2. Transparent ink.
    3. Wrong ink system.
    4. Scanty ink transfer.
  • Solution
    1. Reduce amount of thinner.
    2. Use opaque color shade.
    3. Use pad printing ink.
    4. Locate defect in cliche or pad.
  • Problem
    1. Insufficient etching depth.
    2. Areas not screened.
    3. Areas not slanted.
    4. Wrong cliche type.
    5. Wrong screen ruling.
  • Solution
    1. Use new cliche with greater etching depth.
    2. Screen area.
    3. Slant areas.
    4. Use cliche which allows screen to be etched with it.
    5. Test new cliche with different fineness of halftone screen.
  • Problem
    1. Too flat.
    2. Porous surface.
    3. Too soft.
  • Solution
    1. Use more tapered pad shape.
    2. Replace pad.
    3. Use harder pad.
  • Problem
    1. Soiled surface.
    2. Dark substrate color.
    3. Surface too rough.
    4. Stress cracks (esp. on injection molded parts).
  • Solution
    1. Clean surface with alcohol.
    2. Double print.
    3. Use harder, more tapered pad.
    4. Use milder ink/thinner system or quick drying ink/thinner to avoid any disSolution
    of substrate.
  • Problem
    1. Soiling from greasy residues on accessories (auxiliaries).
    2. Doctor blade sags..
  • Solution
    1. Clean cliche, doctor blade, etc. before installing.
    2. Use harder or thicker doctor blade (or see cliche points 2 and 3).

This Problem very often occurs in pad printing, and cannot always be solved satisfactorily. Due to the low degree of ink transfer in pad printing, 100 % opacity cannot be achieved on many objects with only a single printing, especially in the case of dark substrates. Increased hiding power can be attained by double or triple printing or preprinting with white.

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Dried out on pad.
    2. Too wet on pad, not tacky.
  • Solution
    1. Use slower thinner.
    2. Use faster thinner.
  • Problem
    1. Insufficient etching depth.
    2. Etched too deeply.
    3. Wrong screen ruling.
  • Solution
    1. Produce new cliche with greater etching depth.
    2. Produce new cliche with shallower etching depth.
    3. Use new cliche with different fineness of halftone screen.
  • Problem
    1. Wrong shape pad.
    2. Surface roughened.
  • Solution
    1. Use more tapered pad shape.
    2. Replace pad.
  • Problem
    1. Soiled surface (grease, oil, perspiration, mold release agents..).
    2. Surface insufficiently pre-treated (polyolefines).
  • Solution
    1. Pre-clean objects.
    2. Check pre-treatment, repeat as required.
  • Problem
    1. Print speed setting too slow.
    2. High ambient (room) temperature.
  • Solution
    1. Maintain uniform cycle time.
    2. Optimal room temperature is
    18 °C – 20 °C or
    65 °F – 68 °F.

Incomplete or spotty deposit of ink by pad is referred to as “splitting.” It plays a minor role in a continuously running process. The Problem only arises when cycle times fluctuate or after short breaks. The pad deposits the dried ink all at one time, producing an inconsistent image. Using fast thinners will decrease ink build-up and improve ink deposition.

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
  • Solution.
  • Problem
    1. Individual motifs not correctly aligned.
  • Solution
    1. If motifs are all on one cliche, film must be corrected and new cliche must be produced.
  • Problem
    1. Pads mounted off center.
    2. Pads not same shape.
    3. Pads not of same hardness.
    4. Head stroke not same over cliche and substrate material.
  • Solution
    1. Readjust pad.
    2. Replace pads with ones of correct shape.
    3. All pads should be of same Shore hardness.
    4. Adjust head stroke.
  • Problem
    1. Material is pliable.
  • Solution
    1. Switch to different material.
  • Problem
    1. Jig not perfect.
    2. Carre, adjustable, or rotary indexing table inaccurate.
    3. Mounting screws not tight.
  • Solution
    1. Check for play in jig, refabricate as needed.
    2. Check indexing.
    3. Screws not properly tightened during initial setup; they become loose during printing operation. Tighten screws.

The simplest way to contain these deficiencies is to produce a new cliche with precisely registered film.

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
  • Solution.
  • Problem
    1. Motif not aligned with cliche.
  • Solution
    1. Hold film over finished print and compare; correct and produce new cliche as needed..
  • Problem
    1. Wrong pad shape (pad too small).
    2. Too soft or too hard.
    3. Stroke force too great.
    4. Stroke force on cliche and substrate not equal.
    5. Touch down at wrong point.
  • Solution
    1. Test different pad shape.
    2. Test other hardnesses.
    3. Decrease the head stroke.
    4. Correct the head stroke.
    5. Align pad to correct contact area.
  • Problem
    1. Very soft/pliable.
    2. Material allows distortion.
    3. Very deep recesses/depressions.
    4. Edges in proximity to motif.
  • Solution
    1. Cool objects before printing to harden material; inflate hollow body.
    2. Switch to different material.
    3. and 4. Use pad assemblies or jigs which compensate for depressed areas; produce special pad as needed.
  • Problem
    1. Unsuitable jig.
    2. Work piece mounted at wrong angle.
    3. Jig too unstable.
  • Solution
    1. Modify jig so that substrate is supported in all print/contact areas.
    2. Test correct angle using adjustable wedge.
    3. Produce new jig.

Distortion means that a printed rectangle, for example, does not show any right-angled corners, and has more the shape of a cushion. Distortion occurs primarily in very curved motifs or in motifs which are in proximity to an edge of the area to be printed or of the substrate. It is often impossible to achieve a 100 % correction. It is possible to make a wraparound print, but improvements with this method are also limited.

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Too thick.
    2. Too thin.
    3. Too slow.
  • Solution
    1. Add thinner.
    2. Use new ink.
    3. Use faster thinner.
  • Problem
    1. Poor etching.
    2. Etching too deep.
    3. Wrong cliche type.
    4. Wrong screen ruling.
  • Solution
    1. Examine cliche with magnifying glass, produce new cliche as needed.
    2. Produce new cliche with shallower etching depth.
    3. Replace with correct cliche.
    4. Test new cliche with different fineness of halftone screen.
  • Problem
    1. Too soft.
    2. Wrong shape.
  • Solution
    1. Use harder pad.
    2. Test different shape.
  • Problem
    1. Soiled surface.
    2. Not free of distortion. 3. Great differences in height.
    4. Printing in proximity to edges.
    5. Very structured surface.
  • Solution
    1. Pre-clean with alcohol.
    2. Switch to different material.
    3. Use pad assembly or special pad.
    4. Jig should support substrate adjacent to edges, to prevent pad from extending over edge.
    5. Use hard, pointed pad.
  • Problem
    1. Jig unstable.
    2. Fast cycle time with bulky pad.
  • Solution
    1. Refabricate jig.
    2. Reduce speed, adjust setting to delayed cycle in front position to prevent pad from wobbling during print stroke.

Blurred print is understood as the indistinct, hazy reproduction of lines or letters. This deficiency is often confused with distortion.

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Too thick.
    2. Too thin.
    3. Ink mixed insufficiently.
  • Solution
    1. Add thinner.
    2. Remix ink.
    3. Mix ink well before pouring into ink trough.
  • Problem
    1. Wrong etching depth.
    2. Wrong screen ruling.
  • Solution
    1. Check etching depth, produce new cliche as needed.
    2. Test new cliche with different fineness of halftone screen.
  • Problem
    1. Surface too rough.
    2. Wrong shape.
    3. Oily surface.
  • Solution
    1. Replace pad.
    2. Test different shape.
    3. Clean with alcohol or replace pad.
  • Problem
    1. Soiled surface.
  • Solution
    1. Pre-clean with alcohol.
  • Problem
    1. Ink contaminated by grease, oil, silicone, etc.
  • Solution
    1. Use new ink and keep accessories free of contaminants, or clean before use.
INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Too thick.
    2. Too slow.
  • Solution
    1. Use new ink.
    2. Use faster thinner.
  • Problem
    1. Too deep.
    2. Wrong screen ruling.
  • Solution
    1. Produce new cliche with shallower etching depth.
    2. Test new cliche with different fineness of halftone screen.
  • Problem
    1. Rough surface.
  • Solution
    1. Replace pad.
  • Problem
    1. Very slick, dense material structure..
  • Solution
    1. Substrates where surfaces cannot be dissolved by thinner are esp. problematic (e.g., glass).
  • Problem
    1. Insufficient pretreatment or subsequent treatment.
  • Solution
    1. Heat objects before printing, or ventilate them for thinner to evaporate faster.

During high speed printing operations, the last ink printed may be removed by next pad. This occurs particularly on larger surfaces, where material cannot be dissolved by thinner, or with slower inks in connection with carree or rotary indexing tables and linear belts. The Problem hardly ever arises when adjustable tables are used. The best Solution is to pre-heat objects or dry them with cold or hot air at intervals during the printing run.

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Too thin.
    2. Wrong ink system.
    3. Wrong color match (in custom colors).
    4.Transparent ink.
    5. Shade cannot be mixed.
  • Solution
    1. Use new ink.
    2. Use pad printing inks.
    3. Check proportions or re-mix as needed.
    4. Use more opaque ink.
    5. In this case no Solution
    possible.Test another ink system.
  • Problem
    1. Wrong etching depth.
    2. Wrong screen ruling.
    3. Wrong type of cliche.
  • Solution
    1. Check etching depth or produce new cliche as needed.
    2. Test new cliche with different fineness of half tone screen.
    3. Replace cliche.
  • Problem
    1. Wrong pad shape.
    2. Surface too rough.
  • Solution
    1. Use hard, pointed pad.
    2. Replace pad.
  • Problem
    1. Dark substrate color.
    2. Changing material types..
  • Solution
    1. Try to attain thicker ink deposit by double printing.
    2. See below.
  • Problem
    1. Only printed once.
  • Solution
    1. Test double or triple printing.

This Problem occurs frequently in pad printing. It is, however, often impossible to achieve the original shade, as it cannot be mixed from the colors available in pad printing. To lessen the influence of the substrate color, the options are to: pre-print using white, double print, or triple print to increase the opacity. Each method does, however, have its drawbacks, and should be tested beforehand.

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Too thick.
    2. Ink build-up on pad.
  • Solution
    1. Add thinner.
    2. Use faster thinner.
  • Problem
    1. Etching too deep.
    2. Wrong screen ruling.
  • Solution
    1. Produce new cliche with shallower etching depth.
    2. Produce new cliche with fine half-tone screen.
  • Problem
    11. Wrong pad shape.
    2. Surface too rough.
  • Solution
    1. Use more tapered pad form.
    2. Replace pad.
  • Problem
    1. Surface becomes charged with static electricity.
  • Solution
    1. Install ionizing unit on printing press.
  • Problem
    1. Humidity too low.
    2. Cycle time too fast.
    3. Intermittent operation of machine.
  • Solution
    1. Raise humidity to approx. 60 % – 80 %.
    2. Reduce printing speed.
    3. Regulate to constant cycle times

Improvement can be achieved by grounding press. Splotches or spiderwebs most often occur with materials such as polystyrene, polycarbonate, or acrylics.

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Too thick.
    2. Too thin.
  • Solution
    1. Thick ink with fast thinner produces visible screen dots.
    2. Thin ink with slow thinner (retarder) causes invisible screen dots.
  • Problem
    1. Etching too deep.
    2. Wrong screen ruling.
    3. Wrong cliche type.
  • Solution
    1. Produce new cliche with shallower etching depth.
    2. Depending on results desired, use finer screen for invisible screen dots or coarser screen for visible screen dots.
    3. Use cliche type suited to screen type.
  • Problem
    1. Surface too rough.
    2. Wrong pad shape.
  • Solution
    1. Replace pad.
    2. Depending on results desired, use more tapered pad for visible screen dots or flatter pad for invisible screen dots.
  • Problem
    1. Surface too coarse/ very structured.
  • Solution
    1. In this case, not the screen dots are visible, but the surface structure.
  • Problem
    1. Poor quality of artwork.
  • Solution
    1. Check screen dot pattern on film or expose in new screen.

Screen dots are desirable for some prints, but not for others. Some photopolymer cliches cannot be produced without a screen, or only with a certain type of screen. With steel cliches, the screen is only exposed in for support of the doctor blade, to allow printing of larger motifs over an entire surface.

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Too thin.
    2. Too slow; ink smears.
  • Solution
    1. Use new ink.
    2. Use faster thinner and/or blow on pad.
  • Problem
    1. Etching too deep.
    2. No graduated etching in fine motif.
    3. Wrong cliche type.
  • Solution
    1. Produce new cliche with shallower etching depth.
    2. Only possible with strip steel/steel cliches.
    3. Use different cliche type.
  • Problem
    1. Surface too rough.
    2. Wrong pad shape.
  • Solution
    11. Replace pad.
    2. Use more acute (more pointed) shape.
  • Problem.
  • Solution
  • Problem
    1. Head stroke set too deep..
  • Solution
    1. Causes crushing; adjust head stroke.

This Problem occurs with cliches having both a large surface and fine lines in one motif, because the surfaces should be etched deeper and with screen, but the lines are to be etched flat and without screen.

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Too thin.
    2. Wrong ink system.
    3. Transparent ink.
  • Solution
    1. Use new ink.
    2. Use another pad printing ink.
    3. Use opaque ink.
  • Problem
    1. Etching too shallow.
    2. Wrong cliche type.
    3. Wrong screen ruling.
    4. Motif not slanted.
    5. Different etching depth..
  • Solution
    . Produce new cliche with greater etching depth.
    2. Use different cliche type.
    3. Test new cliche with different fineness of halftone screen.
    4. Slant motif.
    5. Produce new cliche with constant etching depth.
  • Problem
    1. Wrong shape.
    2. Too soft.
    3. Surface too rough.
  • Solution
    1. Use more tapered pad shape.
    2. Use harder pad.
    3. Replace pad.
  • Problem
    1. Surface structure too irregular.
    2. Soiled surface.
  • Solution
    1. Use hard, pointed pad shape.
    2. Pre-clean objects, e.g., with alcohol..
  • Problem
    1. Doctor blade sags.
    2. Only printed once..
  • Solution
    1. Use stronger doctor blade, or screen areas or slant lines.
    2. Double print or preprint opaque ink.

This deficiency is easily observed in prints where peripheral areas are acceptable, but coverage (hiding) worsens progressively toward center. See also “Insufficient Opacity.”

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Too thick.
  • Solution
    1. Add thinner.
  • Problem
    1. Poor etching.
  • Solution
    1. Examine cliche with magnifying glass; produce new cliche as needed.
  • Problem
    1. Surface damaged.
    2. Wrong shape.
    3. Too soft.
  • Solution
    1. Replace pad.
    2. Use more tapered pad shape.
    3. Use harder pad.
  • Problem
    1. Statically charged.
    2. Contaminated with dust particles.
  • Solution
    1. Install ionizing unit.
    2. Pre-clean. objects, if necessary, using air hose (air jet).
  • Problem
    1. Soiled artwork.
    2. Dust present when films are copied.
    3. Unclean environment, dust circulating in surrounding air.
  • Solution
    . Checks films.
    2. Produce new cliche.
    3. Dust particles, which appear to be air bubbles, can be transferred by pad from substrate to ink.

This deficiency can be contained easily. If bubbles always appear in same place, Problem will be found in cliche or pad. If position of bubbles shifts, Problem is caused by dust particles or electrostatic charges.

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Too thin.
    2. Too slow.
  • Solution
    1. Use new ink.
    2. Use faster thinner.
  • Problem
    1. Etching too deep.
    2. Wrong screen ruling.
    3. Wrong cliche type.
  • Solution
    1. Produce new cliche with shallower etching depth.
    2. Test new cliche with different fineness of halftone screen.
    3. Use different cliche type.
  • Problem
    1. Too soft.
    2. Too little volume.
    3. Prints over edges.
    4. Stroke force on cliche and substrate not equal.
  • Solution
    1. Use harder pad.
    2. Use larger pad.
    3. Correct head stroke.
    4. Correct head stroke.
  • Problem
    1. Very irregular surface.
    2. Surface not sufficiently precleaned.
    3. Material not smudge free.
  • Solution
    1. Use pad assembly or special pad.
    2. Pre-clean surface.
    3. Switch to different material.
  • Problem
    1. Jig not fastened tightly enough.
    2. Jig unstable.
    3. Jig not precisely made, object has too much play.
    4. Cliche not doctored cleanly.
  • Solution
    1. Tighten fixture.
    2./3. Produce new jig.
    4. Sharpen or change doctor blade.

This deficiency often occurs when thinner is added during printing run, where ink and thinner are not properly mixed.

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Wrong ink system.
    2. Wrong or no hardener.
    3. Wrong/imprecise mixing proportions.
  • Solution
    1. Only use ink system suited to substrate according to technical bulletin.
    2. Corresponding hardener must be added to two component inks.
    3. Weigh proportion of ink to hardener exactly.
  • Problem
  • Solution
  • Problem
    1. Oily pad surface.
  • Solution
    1. Clean new pads with alcohol before use.
  • Problem
    1. Soiled surface (grease, oil, perspiration, mold release agents).
  • Solution
    1. Pre-clean substrate with alcohol.
  • Problem
    1. Surface insufficiently or not at all pre-treated.
    2. Curing (drying) time not observed.
    3. Subsequent treatment of surface insufficient or lacking.
  • Solution
    1. Check pre-treatment, repeat as needed.
    2. Observe curing time as per technical bulletin.
    3. Check subsequent treatment.

This Problem frequently occurs because the type of plastic material is unknown, or unsuitable ink systems are used. The requirements for adhesion and scratch proofing are very different due to the respective demands placed on the finished products. It is expressly recommended that the printing material be checked under the respective conditions of use before printing any production run.

INK PLATE PAD SUBSTRATE OTHERS
  • Problem
    1. Wrong ink system.
    2. Insufficient ink transfer.
  • Solution
    1. Use glossy ink.
    2. Double print.
  • Problem
    1. Etching depth too shallow.
    2. Wrong screen ruling.
    3. Wrong cliche type.
  • Solution
    1. Produce new cliche with greater etching depth.
    2. Test new cliche with different fineness of halftone screen.
    3. Use different cliche type.
  • Problem
    1. Surface too rough.
    2. Wrong shape.
  • Solution
    1. Replace pad.
    2. Use more tapered pad shape.
  • Problem
    11. Structure of material unsuitable.
    2. Material unsuitable.
  • Solution
    1. Structure of substrate influences result.
    2. Ink looks matte due to stress cracks.
  • Problem.
  • Solution

This Due to the thin layers of ink inherent in pad printing, it is generally not possible to attain as high a grade of gloss as with screen printing.

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Pad Printing Plate, Silicon Pad, Jig Fixture, Doctor Blade, Consumables

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Different sizes of Pad Printing Plates

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Different types of Pad Printing Silicon Pads


PAD PRINTING PLATE

Pad Printing Steel Plate

Closed Cup Machine or Open Ink Well Machine – Plates No Problem!!! We always have a ready stock of large variety of different sizes of Cliche Plates or Tampon Plates. We have around 40 odd sizes of plates ready for the customer. Our Steel cliches are especially suited to high quantity printing. Tell me more…

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PAD PRINTING DOCTOR BLADE

Doctor Blade, Ink Cups.

We manufacture Doctor Blades which are used for cleaning(Doctoring Operations) on the steel plate. We have various sizes depending on your requirements. We also provide Ink cups upon request. Various other small consumables are also readily available Tell me more…

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PAD PRINTING SILICONE PAD

Pad Printing Silicone Pad

We have around 400 odd different varieties of Printing Silicon Rubber Pads or Tampon pads. Tampons are available in three different Shore A Hardness namely soft, medium and Hard. Round, Square and Rooftop(long) shapes are cataloged. they can be downloaded in PDF format.Tell me more…

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CARROM STENCIL

Carrom Screen Printing

We make Textile Carrom Screen for Screen Printing of Professional Carrom Boards. We have more the 30 designs in carrom.We make carrom screen and supply to almost all carrom manufacturers. Carrom Screen are made for 12″, 15″, 18″, 21″, 24″, 27″, 30″, 36″ & 42″ (sizes in inches).  Tell me more…

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PAD PRINTING JIG FIXYURE

Epoxy, Acrylic Jig Fixture

The fixture is a female cavity of the substrate you want to print on. the accuracy of the fixture is very important. If it not accurate the substrate is move while printing and cause mis-printing.We make fixtures from 4 different types of materials Epoxy, Acrylic, Nylon and Teflon Tell me more…

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SCREEN PRINTING SUPPLIES

Screen Printing Supplies

e manufacture and sell screen stencils of various sizes in wooden or metal for screen printing machines.We manufacture our own Screen Emulsion. Screen Emulsion is available as a very reasonable rate. Indian as well as Imported Squeegee is also available with us.. Tell me more…

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