1. It’s the only manual press that can expand from 4 colors to as many as 10 colors, and from 8 colors to as many as 14 colors. Color expansion doesn’t enlarge the footprint of the press.

2. It’s fully compatible with M&R’s Tri-Loc registration system, which speeds setup.

3. It supports automatic presssize screen frames. This means operators never have to buy screen frames that can’t be used on an automatic. Once they decide to automate, they won’t be faced with replacing thousands of dollars of manual-only frames.

When should I consider automating my T-shirt shop?

Automatic presses have become amazingly easy to run. Setup can be fast and easy with registration systems like M&R's Tri-Loc. Automatic presses typically run up to 10 times faster than manual presses, usually with better print results. A single operator, working alone, will produce 3-5 times the volume of an operator running a manual press. Automatics take less physical effort to run, so operators of automatics experience less fatigue. Operator fatigue often leads to production decline over the course of a day. Since labor is usually the largest expense in any screen shop, making labor more productive goes a long way toward defraying the cost of an automatic. Increases in productivity can also make for more efficient use of space. Generally speaking, the automatics that will fit into a given space will produce more than the manual presses that will fit into the same space. This means automating can buy time for an expanding business by delaying the time the business will run out of room and have to move to a larger facility. Finally, there is the issue of volume. An automatic press provides proportionately greater benefit to a shop with large press runs. Since setup time on automatic and manual presses is similar, the time it takes to set up and print a single shirt on a manual press would differ little from the time it takes to set up and print one shirt on an automatic. However, the more shirts there are in the print run, the greater the advantage of an automatic.

What's an oiler and how does it work?

An oiler is a device designed to lubricate components and protect parts from corrosion by injecting oil into pneumatic lines. An oiler is usually part of a lubricator/filter/moisture trap assembly located at the point where pressurized air enters the press. The purpose of this assembly is to protect all the pneumatic components of the press from particulate and moisture contamination. Failure to supply the equipment with clean, moisture-free air may result in premature failure of pneumatic components such as air cylinders, seals, and valves. Air coming straight from a compressor is laden with moisture. This can be very damaging to the small moving parts inside air-driven components. The first line of defense against moisture should be a refrigerated chiller/air dryer, installed between the compressor and press. This device condenses the moisture in the air and removes it from the line. The filter removes particulates from the air, preventing them from damaging pneumatic components. The final device in the assembly injects oil into the line. The oil lubricates pneumatic components, preventing corrosion, and reducing friction and wear. Most oilers are adjustable and should be set to inject at factory-recommended rates. Oilers should be checked regularly to make sure oil level is maintained. M&R equipment requires #10 non-detergent oil.

What’s the difference between infrared and quartz-infrared flash cure units?

Infrared flash units are less expensive to purchase, and simpler to set up and operate. Quartz-infrared flash units are more expensive, but offer significant advantages, including:
1. Faster curing.
2. Instant on/off operation.
3. Space savings because they mount over the print station and remain in place, rather than sitting outside the carousel and shuttling in and out
4. More precise control over curing

How fast should I be able to print?

Press cycle speeds vary. For example, Challenger II cycles at speeds over 90 dozen per hour, Formula at over 110 dozen per hour. However, cycle speed is not the same as print speed. A cycle is one full print stroke, from the start of the first print stroke to the same point at the start of the second stroke. The term is usually used to represent the rate at which a press can operate when it is not printing. In the non-printing mode, the press is not affected by things like the type and consistency of the ink used, mesh count, screen tension, coverage required, and operator experience. To varying degrees, each of these factors helps prevent the press from printing at the cycle rate. Although one or more of these factors can slow press operation, maximum press speed is usually determined by how fast the operator can load T-shirts.

What can I print on my M&R textile press?

While this may seem like an unnecessary question, there are many textile products that don’t get the attention T-shirts, sweat shirts, and jackets do, but can be printed on nonetheless. Creativity and knowledge of ink will allow you to print not just on cotton, cotton denim, and cotton blends, but on nylon, polyester, Gore-Tex®, Suplex® and other synthetic substrates. That same knowledge, and possibly a specialized pallet, will allow you to print on products that include towels, scarves, swim trunks, pant legs, shirtsleeves, and socks.

What can I do when I need to print youth long sleeve shirts? And get the most production possible out of my sleeve print orders?

M&R’s patented Triple Play Pallets address a wide range of printing needs. The torsion bar support system enables outrigger-style pallets to handle heavy print loads without flexing or drooping. It also allows users to load small-size long-sleeve shirts without interference from the pallet leveling bracket. And operators can load more than one garment at a time, effectively doubling press production. The sleek design and large cutouts maximize clearance for large or bulky garments, and the center pallet is especially effective for garments like Toddler T's and shorts. The rubber-covered printing surface helps enhance print quality. Triple Play Pallets are available in a wide range of sizes and styles.

What is a Tri-Loc? And how can it save me time?

The Tri-Loc is a Pre-registration system is designed to speed screen setup and registration on M&R presses. Used correctly, it can reduce setup times by as much as 90%.

Traditionally, screen registration has been done on the press, one print and one color at a time. Traditional registration can take up to 2 hours. That’s a huge amount of downtime for a press that should spend as much time as possible in production. The Tri-Loc system takes the time-consuming task of registering screens on the press and shifts it to a pre-press area so that production won’t be affected. That’s not to say registration time is eliminated; it’s just moved in order to free up the press for what it’s designed for: high-speed production. Tri-Loc lets users register films and screens in the pre-press area, and then take those “pre-registered” screens and, with the help of the Tri-Loc pallet, quickly re-register them on the press.

Tri-Loc becomes part of a complete proofing system when combined with M&R’s Chameleon, Sidewinder, or Pre-Runner press. Quick setups allow for pre-press color checks and final design proofing before going into production. And since the operator no longer needs to look through the screen for registering, the screens that were used to sample don’t need to be cleaned, saving time and supplies.

How does Tri-Loc work?

In the Art Department, films are aligned and attached to carrier sheets (having someone manually align and check every film for things like missing colors or films that may not properly align helps to catch any issues early in the process). Once films have been aligned, they are sent to the Screen Department for exposing. Here the operator simply mounts the film and carrier sheet on the Tri-Loc master frame, and then loads and exposes the screen. As soon as screens are blocked out and taped up, they’re ready for production.

At the press, one printing pallet is removed and replaced with the Tri-Loc pallet. This pallet has three stop blocks that mimic the blocks of the exposure unit master frame. The pallet is indexed around to each print station and raised into position. The screen is simply pulled into contact with the stop blocks, re-registering what was started in the Art and Screen department. With a Tri-Loc, the operator no longer needs to look through the screen for a printed image to align to.

What is a Pneumatic Squeegee Pressure Regulator?

Pneumatic squeegee pressure regulators allow precise, repeatable squeegee pressure from pallet-to-pallet by controlling the air pressure going to the squeegee cylinders. The advantage over mechanical adjustment is that the squeegee actually compensates for pallets that aren’t level and for slight variations in garment thickness. Another advantage is that you can change squeegee blades or squeegee angles without having to make mechanical Adjustments. The squeegee pressure regulator also displays true squeegee pressure, so the operator can set the identical pressure the next time there’s a job with the same parameters.

What is the "Revolver" Print Program?

M&R’s patented Revolver Print Program enables M&R press owners to get the most out of their presses by allowing the press to make multiple revolutions on a design that may require more print and flash stations than are available on the press. Revolver is especially helpful on 6 and 8-color presses. Revolver allows printing in every head while flash curing at the unload station. Even larger presses benefit from the Revolver program. For example, on a 12-color press running a 10-color job with two flash cures to handle specialty inks that must be flashed three times, the revolver can print 3 colors; flash; then print 4 colors and flash on the first revolution. On the second revolution, the press can print 2 more colors and flash before printing the final color.

Countless other scenarios are well within Revolver’s reach.

What is the purpose of Central Off-Contact?

Central Off-Contact changes the height of all pallets simultaneously. It’s beneficial when changing garments or other substrates in the middle of a run. For example, when switching from T-shirts to sweatshirts, the operator needs to change the Off-Contact distance for every pallet. Central Off-Contact allows the operator to change the settings on the lower carousel without affecting the screens or registration in any way.

What’s the purpose of Rasta Bars and when should they be used?

Unlike Central Off-Contact, which changes the height of all pallets simultaneously, M&R’s Rasta Bars are a color-coded set of highly accurate steel shims that can be used to change off-contact on individual printheads. This is especially beneficial in setting up a job that requires high ink buildup (high density & certain gels) when only one screen needs to be adjusted. The advantage of Rasta Bars is that you don’t have to change the off-contact; you simply set the appropriate Rasta Bar or combination of Rasta Bars on the front and rear frame holders before loading your screen. When you’re finished, you simply remove the Rasta Bars to return the printhead back to its original setting. This approach helps maintain overall press calibration.

What is the purpose of a Pallet Locator Arm?

The Pallet Locator Arm provides a quick and repeatable way to locate pallets in the same position from arm-to-arm.

What is M&R’s System Integration™ and how does it benefit me?

System Integration is M&R’s way of making sure each M&R customer gets maximum return on investment. First, M&R makes sure each piece of equipment stands on its own as the industry’s best in class. But M&R doesn’t stop there. M&R designs products that work together as part of a seamless integrated system, products like Chameleon, which uses frames and pallets that are interchangeable with M&R’s Automatic Presses. And products like M&R’s Tri-Loc & Double Tri-Loc Rapid Registration Systems, which pre-registers screens allowing quick setup on M&R’s automatic and manual presses. In fact, all of M&R’s manual and semi-automatic sampling/short-run presses are compatible with automatic-type screen frames & pallets and with NuArc’s Helios and Tri-Light Exposure Systems. And you can use the Pre-Runner sampling press with Tri-Loc and automatic-type screen frames for ultra-fast registration and color sampling. Since the screens on the sample press can be carried directly to any M&R textile automatic, your automatic presses spend their time engaged in their specialty: high-speed production.

Most M&R flash cures are designed to work with all M&R automatic & manual presses. In addition, M&R’s new Z Series flash cure units are designed to be operated directly from the control panels of M&R new “Z” series automatic presses.

The bottom line is that M&R makes the fastest integrated sampling/production system in the industry. Combine any M&R sampling press with Tri-Loc or Double Tri-Loc for up to 95% faster setup and maximum short-run productivity.

An integrated M&R system also means a single point of contact for customer service, technical support, training, and sales. Every piece of M&R equipment is ruggedly built with M&R's unsurpassed commitment to quality, durability, and design excellence, and is backed by M&R’s unparalleled service and support. With an M&R System, you get all that plus everything you need to run faster, run smarter, and run up your profits.

What is the difference between cycle speed and print speed?

A cycle is one full print stroke, from the start of a print stroke to the same point at the start of the next stroke. The term is usually used to represent the rate at which a press can operate when it is not printing. In the non-printing mode, the press is not affected by things like the type and consistency of the ink used, mesh count, screen tension, coverage required, and operator experience. To varying degrees, each of these factors helps prevent the press from printing at the cycle rate.

How long should the infeed and outfeed on my dryer conveyor be?

These lengths vary depending on (a) the maximum size of the stock you plan to print and (b) whether or not you plan to employ a takeoff. Without a takeoff, the infeed and outfeed have to be long enough (and wide enough) to accommodate a full sheet of stock. If you plan to use a takeoff in an in-line setup, the conveyor infeed must be at least the length of the takeoff. If you plan to use a right-angle setup, the conveyor belt must be wide enough to accommodate the long dimension of the stock. Since takeoff placement accuracy declines as production speeds increase, the conveyor should be somewhat wider that the length of the stock. Note: a right angle setup is not practical for larger presses, like M&R’s Patriot, Patriot LS, Renegade XL, and Renegade LS, because of the limitations on dryer width.

What is the Park feature?

Park allows the press operator to retract (lift) both the squeegee and floodbar. Once they’re away from the ink and screen, the press can be cycled (the head moved forward and/or back) without flooding or printing.

What are zoned vacuum beds?

Zoned vacuum beds allow operators to limit vacuum to the area under the substrate. Operators set the vacuum zone by pulling a knob or turning a dial. A zoned vacuum system speeds setup and tear-down since it eliminates the need to tape off areas outside the substrate footprint.

What’s an oiler and how does it work?

What's the advantage of being able to index in either direction on a multi-color graphic press?

During proofing, the operator can alter the order of screen/color application on test prints without having to tear down and set up for each variation.

What's the purpose of adjustable UV lamps?

Curing requirements vary with the type and thickness of substrates. Adjustable-focus UV lamps can be focused to cure heat-sensitive substrates (like vinyl) or unfocused for heavier, less sensitive substrates (like glass and metal).

Are takeoff systems for flatbed presses cost effective?

In most cases, takeoff systems are extremely cost effective. They reduce costs by eliminating the need to have an employee remove substrates after printing. Fast, effective, and consistent, M&R takeoff systems also help increase print speed while protecting substrates.

What is SystemSaver™?

M&R’s SystemSaver automatic shutdown sequence keeps the blower and belt running until the chamber has cooled. This is especially important in extending the life of the conveyor belt.

How does dual-reflector technology work?

M&R's Dual-Reflector System (U.S. Patent No. 5 216 820) uses a secondary reflector—positioned at the top of the primary reflector—to capture the energy that normally bounces down onto the lamp. The secondary reflector redirects this UV energy onto the substrate, speeding the curing process while saving energy and prolonging lamp life. M&R’s unique open-top reflector chambers enhance the curing process by allowing heat and ozone to escape.

M&R's Switchback and Vitran II UV Cure Systems use dual-reflector technology. See the PDF brochures for a graphic depiction of dual-reflector technology.

What is a Switchback Dryer?

M&R’s Switchback dryer allows the operator to select among three (3) different lamp types (Mercury Vapor, Iron Oxide, and Gallium). All the operator has to do is change the lamp. There’s no need for tools and there are no jumpers to move. This dramatically enhances the operator’s ability to select the ideal cure for any substrate/ink combination.

How does M&R's Dripless Squeegee work?

The dripless squeegee attachment automatically flips to the opposite direction against the front of the floodbar before the flood stroke begins, preventing ink from dripping into the image area. That may seem like a minor benefit, but ink that drips onto the image area of the screen can seep through the open mesh. More ink will then be screened onto the substrate where the drip landed, adversely affecting print quality.

What's Job Recall™?

Job Recall is M&R's system for storing and recalling numerous standard and optional functions and settings under operator-chosen alphanumeric names. On presses, these can include dwell time; index speed; off contact; peel ratio; print stroke and flood stroke length & speed; squeegee pressure (electronically adjusted air pressure); and wattage settings on UV cure units.

Available on many M&R graphic presses, Job Recall speeds job setup and changeover. Once an operator has fine tuned settings for a particular job, he/she can assign a name to those settings and then store them in the memory of the press. The next time a similar job is run on the press, the operator can simply call up that job name to have the appropriate settings automatically applied to the press. If a new job is similar to a stored job, but different in one or more aspects, the operator can modify some settings and store the new job settings under another name.

Job Recall dramatically speeds job setup and print consistency.

How does M&R's Ink Dip System work?

M&R’s Ink Dip System allows the operator to pick up ink that has run past the flood bar by setting the squeegee to periodically move beyond the set stroke length. The operator can set the number of print cycles between each Ink Dip procedure.

What is flat flood?

Flat flood moves the screen to a position level with the printing cartridge prior to flooding. This gives the operator an even and consistent flood.

What's the advantage of a double-sided sheet locator?

On multi-color presses running double-sided work or “work and turn” jobs, the double-sided sheet locator allows the operator to register the substrate at any of the four corners.

What's the value of independent vacuum and blowback?

This allows the operator to adjust for different substrate weight, and thickness. Independent vacuum and blowback can be timed before or after the print. These settings can also be stored in Job recall.

Where can I get information about printing techniques?

Check out the Articles and Tips section of our website. We offer a full range of technical information. You can also check out www.screenweb.com or www.sgia.org.

Why should I buy from M&R?

1. Quality: We manufacture most of our parts in our state-of-the-art facilities, using only the finest materials and components. Our machining and milling equipment is the finest, most modern available, as are our robotic welders and plasma cutters. All M&R equipment is painstakingly manufactured to meet our engineers’ exacting specifications.

2. Innovation: We’re on the cutting edge, with products like the first successful two-tier (Duo-Deck) manual press (Chameleon), the patented dual-reflector UV cure system (Vitran, Switchback, Processor, & Advantage), and the first successful auto-unloader for textiles (Passport).

3. Service & Support: With all of our resources, our network of distributors, our after-sale technical support, 24/7 service hotline, parts warehouses, and the wide range of products available from M&R and our sister companies, Amscomatic & NuArc, M&R simply offers more for your dollar in the long run. No matter where you are or where you want to go, M&R has the products to get you there.

Does M&R offer training?

M&R offers maintenance and repair training to our customers at our Glen Ellyn and Niles Facilities located in Illinois, USA. Contact the M&R Service Department at 800-736-6431 for more details.

Does M&R sell used equipment?

We don’t sell used equipment, but we maintain a Used Equipment section as a free service to our customers. Anyone wishing to sell used M&R equipment can post it on our site. We do not take part in these transactions, nor do we have a financial interest; we simply provide a means by which buyers and sellers can get together. There is no charge to list used M&R equipment for sale, and we impose no fees of any kind on buyers or sellers. If you are interested in buying or selling used M&R equipment, go to the Used Equipment section and fill out the form provided.

How long will my M&R press last?

There is no way to predict exactly how many years a press will run or how many impressions it is capable of making. However, we have customers who say their M&R presses have exceeded 10,000,000 prints and are still running strong. A few customers tout over 15,000,000 prints on M&R presses that are still in daily use. Obviously, we can’t tell you how long your M&R press will last, but if you start with M&R quality and stick with proper use and maintenance, your press should last a very long time.

How long is M&R’s warranty?

Most M&R textile machines carry limited two-year warranties and most M&R graphic, Amscomatic and NuArc machines carry limited one-year warranties.

What is the difference between a Point Light Source and a Multiple Light Source?

The Point Light Source has always been the best source of light for exposing litho plates, proofing materials, film, and screen printing frames. A Multiple Light Source uses either a bank of UV fluorescent lamps or a bank of UV fluorescent lamps in combination with a quartz halogen lamp. Multiple light source units became popular primarily because of their low cost. For this reason, they’re the choice of many of those just starting out in screen printing. However, if price is the advantage of multiple light source units, high-quality detail is the advantage of point light source units. Larger shops intent on doing higher quality work will definitely want the far superior point light source. Even smaller startup shops should seriously consider starting out with a point light source. If that’s not possible when starting out, the small shop owner should make plans to upgrade as soon as possible. The benefits, which include fewer re-burns and happier customers, are well worth the added cost.

NuArc’s First Light and Mega-Light UV Fluorescent Exposure Systems use multiple light sources. Both units are versatile and affordable, and represent ideal solutions for startup manual screen shops. All the other exposure systems in NuArc’s lineup, from the MSP 2125 through Helios and Helios T, employ a point light source.

Is vacuum important for exposing screen printing frames?

It is very important, but especially so for fine detail and half tones. If you want the best reproduction, you need to have the film solidly against the emulsion on the screen fabric. Failure to do so will reduce image sharpness as light bleeds under opaque portions of the film. The result is not unlike the difference between the sharp edges of a laser beam and the fuzzy edges of the beam from a flashlight. Creating a vacuum allows atmospheric pressure to draw the blanket and glass together under more pressure than can be achieved in any other practical way. The vacuum ensures that the film is held against the emulsion under uniform pressure, assuring intimate contact between the two. For the very best results, combine a high-quality vacuum frame with an equally good point light source.

All NuArc exposure systems rely on vacuum drawdown to ensure the closest film-to-screen contact and the sharpest images.

What does an Integrator do, and what benefit do I get from having one on my exposure unit?

An integrator is an electronic device used to measure the quantity of light emitted by a lamp. Once an exposure test is made to determine the quantity of light needed by a particular emulsion, the integrator will keep the lamp on until that quantity is reached. If the amount of light emitted by lamps did not degrade over time, operators would be able to develop a set exposure time for each emulsion type. However, since lamps do degrade, calculating proper exposures without an integrator becomes very difficult. Integrators enhance your control over the screen-making process and ensure precise repeatability. Each screen will receive the same quantity of light by taking into account the aging of the lamp and the voltage on the line.

What is the difference between Metal Halide, Mercury Vapor, and Quartz Halogen light sources?

Metal Halide and Mercury Vapor are two similar types of gas discharge lamps that output light in two different areas of the UV spectrum. Both lamps create light by heating up metal additives. Most of today’s emulsions perform best under the spectral output of the metal halide, so it has become the most popular light source. In fact, some modern metal halide lamps are multi-spectrum lamps. Their specialized metal additives cover a wider spectrum in order to match a broader range of emulsions.

Although Quartz Halogen lamps have been used for screen making, they produce a very poor light source. The quartz halogen lamp is basically a high-wattage incandescent lamp that emits a lot of white light but very little of the UV that emulsions require. It’s ironic, but some people invest in what they think is a high-quality exposure system and then compromise performance by using the wrong light source.

Metal Halide is the best light source for today’s emulsions, but be aware that not all metal halide lamps are the same. Those designed to light a warehouse or parking lot have additives that give off more visible light. The light source that provides the best results and fastest screen exposures peaks out in the 350-450 nm range.

What is the difference between a Shuttered light source and an Instant Start light source?

Lamps in “instant start” units turn off between exposures, saving energy and reducing heat buildup. These units are typical in shops with low-to-medium production requirements. Lamps in “shuttered” units stay on all the time, but they return to standby (low output) mode between exposures. Since the lamp remains on, shutters close when the blanket frame is opened in order to protect the screen from unwanted light exposure. These units are typical for high volume shops.

NuArc offers both types: the instant-start Tri-Light and the shuttered Tri-Light ST and Tri-Light CTS.

What are the benefits of the Tri-Light CTS?

The Tri-light CTS was designed to meet modern screen making techniques. Computer-to-screen or ink jet-to-screen systems will continue to replace film. Tri-Light CTS has a unique dual-vacuum-frame assembly that enables it to handle both computer-to-screen and film-based screens. Screens can be exposed with film by using the upper vacuum frame. As with the standard Tri-Light, vacuum is applied to ensure intimate contact between the blanket, screen, and glass. The CTS system has the ability to bypass the glass by using a rack for computer-generated screens. Instead, screens rest on an adjustable rack. Screens generated by computer or ink jet do not come into contact with the glass, preventing smearing of the image prior to exposure.

What is NuVac?

NuVac was created by NuArc and is exclusively used on NuArc’s Helios large-format screen exposure system. Many large-format systems have problems removing the air between the screen and glass, but the NuVac System is designed with two vacuum pumps and 2.54 cm (1”) strips sandwiched between twin blankets. The air between the blankets is drawn out, causing the strips to press against the screen and then onto the glass, creating channels for the air pocket to escape. This process ensures intimate contact between the screen and glass. Prior to exposure, the outer blanket is released while the inner blanket remains under vacuum to provide a smooth surface during exposure.

What are the benefits of self-contained exposure units?

Self-contained exposure units prevent the light leakage that can ruin coated screens by prematurely exposing them. Because exposure cannot take place unless the lid is closed, self-contained exposure units can be placed in darkroom with coated screens. Putting the exposure unit adjacent to the coated screens protects emulsion and increases productivity. Self-contained exposure units also take up less space than a separate vacuum frame and light source.

What’s the advantage of lamps with multiple wattage settings?

Lamps with multiple wattage settings provide increased control over emulsions with very short exposure times. In essence, by reducing wattage and increasing exposure time, the operator has a greater margin of error. Where a one-second difference might be critical on a highly sensitive emulsion exposed at a 6K setting, that single second is far less critical when exposed at the 3K or 1K setting. NuArc’s System 631 is a production-proven light source that gives the operator the ability to change the wattage of the lamp by selecting 6K, 3K or 1K. It’s an ideal choice for those who deal with extremely fast emulsions.

What are the benefits of vertical automatic centering lamps?

Typically, large format exposure unit lamps are centered for the largest screen the unit can handle. That provides the proper exposure for the largest screen size, but leaves smaller screens off-center where they’ll be unevenly exposed.

Automatic centering lamps are found exclusively on larger models of NuArc’s Helios large-format exposure system. The operator simply punches in the correct screen size and the Helios will center the lamps. The result is a fast, even exposure.

What costs are involved in setting up and running a finishing operation?

Costs include those for:

Bags or bagging material
Equipment
Labor
Overhead

The key components are equipment and labor. To automate or not basically comes down to the question of whether or not equipment cost and the advantages of improved efficiency and product presentation are less than the higher labor cost and reduced efficiency found in the manual finishing process.

Finishing operations can be fully or partially automated. Amscomatic has equipment for virtually every finishing application. Whether you're looking for a single semi-automatic tagger or a complete folding/tagging/bagging/sealing/labeling/stacking/boxing solution, Amscomatic is the place to turn.

Why should I consider adding automatic or semi-automatic finishing equipment to my production line rather than just hiring a few temps to take care of it?

Like it or not, our industry is being called upon to provide more services to our customers, as they try to find ways to improve their efficiency. A packaged product which is neatly folded, labeled or tagged for convenience, protected for shipment and during storage, and which is traceable through a bar-coded label applied to the garment or the bag can be a very attractive time-saver for those customers. Though much of this "finishing" work may have historically been done manually, the increased demands are causing many printers and embroiderers to consider investing in automated machinery. For many, an automated line's increased efficiency will quickly justify the investment required.

Folding and packaging is also a great way to differentiate yourself from your competitors, and can offer a nice new revenue stream to pad your bottom line. Along with the advent of newer, more automated technologies come opportunities for garment decorators to realize increased consistency of product presentation, increased efficiency and increased profits.

How will I know if it's time for me to automate my product finishing process?

The answer varies with your production quantity, but the sales staff of finishing equipment manufacturers can help you determine which equipment would represent a cost-effective solution in your situation. If the volume is there, the reasons to automate are pretty simple: for many of the same reasons why you bought that fancy Automatic T-shirt press or Multi-Head embroidery machine in the first place. These might include:

Decreased labor costs
Greater profit
Higher production capacity
Improved customer satisfaction
Increased versatility

What are the advantages of folding, bagging, and tagging?

The advantages include:

Added-value can allow higher profit margin
Advertising on printed poly bags or packaging
Appearance of final product
Competitive Edge in your market
Consistency of product presentation
Low cost of package vs. other types of packaging
Protection against soiling
Tracking via labeled bags

What products can be folded and bagged?

Products that are well-adapted to the folding/bagging process include:

Dresses
Golf Shirts
Lightweight Jackets (some types)
Long Sleeve Shirts
Pants
Polar Fleece
Sweatshirts
T-Shirts

How fast can we expect to fold shirts with automated machinery?

Speed will vary depending upon the machine, the product and the operator. Amscomatic machines can fold as many as 1800 or more garments per hour. Compared to a single operator folding manually, this represents more than a tenfold increase in production speed.

Amscomatic's sophisticated K-840 & K-895 folders are the ideal solution when the goal is high-speed, high-quality folding. And a significant technological breakthrough — M&R's patented bottom pulling dual-belt (upper & lower) transport system — finally makes it possible to fold garments printed with high-density and gel inks.

Some of my customers require a cardboard stiffener in the folded garments can this process be automated?

Yes, the Amscomatic CF-100 will automatically insert a chipboard or stiffener into each garment during the folding process, greatly increasing efficiency.

How many people are required to operate a folding/bagging station?

Most operations will use two or three people, depending upon volume. One person loads the shirt; one bags the product; and sometimes a third person boxes the product and supports the other two employees.

What are the advantages of bagging my product?

The advantages include:

Cost of package vs. other types of packaging
Improved product appearance and presentation
Product protection
Product Tracking via labels applied to or printed on the bags

M&R offers two bagging systems: the AB-6700 and the Omni-Bagger. The AB-6700 is a high-speed fully automatic bagger. It creates bags from plastic film, without requiring an operator, so it saves labor.

Omni-Bagger is a compact and affordable semi-automatic bag loading and sealing system. It uses wicketed bags, opening them automatically so that an operator can easily load the product by hand. The bag is then sealed automatically.

What types of bags or films does this machinery use?

Baggers can use a wide variety of material formats, from pre-made bags on wickets or rolls, to a center-folded roll of material which is then sealed and cut to form a bag.

What features are available in pre-made bags?

Bags are readily available with numerous types of closure, including:

Flap with tape seal
Fold-over flap
Hanger bags
Header bags
Heat seal
Perforated tear strips
Tamper-evident seal
Zipper-lock seal

How fast is the bagging operation?

Bagging machines are available with speeds similar to folding machines: typically between 300 and 1800 per hour.

Can I use a single bag for multiple products?

Yes. Both the AB-6700 and the Omni-Bagger can be configured to accept single shirts as well as stacks of shirts or garments.

Can the stacking process (prior to bagging) be automated?

Yes, the Amscomatic AS-200 automates the stacking process.

How can I ensure that I have the correct number of shirts in each box?

Production counters at various steps along the production line help ensure accuracy.

How do I select the right size bag for my product?

Bags are generally ordered to your specifications, but try to avoid using a different bag size for every product. If you are simply using the bag as a dust cover, start by sizing the bag to fit your largest product. If the finished fold range varies widely, this should be a "one size fits all" scenario. This is easiest, most efficient, and most cost-effective approach.

However, if the finished package is a retail product, possibly even with advertising on the package, it is important to size the bag to properly fit the finished folded piece. A properly-sized bag is usually a snug fit with no garment distortion. A snug fit also maintains the dexterity of the fold and yields an attractive, professional appearance.

What material should the bag be made of and how thick should it be?

Polyethylene is the material of choice. This poly material is cost effective, easy to work with, and provides good protection for the garment. Polyethylene can be used as either a dust cover or as retail packaging. The higher quality bag is generally 1.5 mils thick. The "dust cover" type of bag typically ranges from 1-1.25 mils.

Other materials, such as Polyolefin, Polypropylene, and co-extruded materials, are available. While they can look very nice, they are more expensive and can be difficult to work with.

What options do I have in my choice of bags?

There are too many pre-made bag options to cover them all here. However, a visit with your local bag supplier can prove to be informative and beneficial. Resist the temptation to place your bag order before you've consulted your bag supplier about all the available choices.

What are the advantages of printed bags?

Printed bags are an outstanding way to get more "bang for the buck," and one of the most overlooked advantages is the opportunity to advertise your company. Printing can be done from one to eight colors. Plates can be designed to print virtually anything on the bag. Company logos, web sites, addresses, contact numbers, and child warning labels are among the more commonly printed bags.

Minimum order points usually start at 10,000 pieces. Price breaks usually start at about 50,000 pieces, and higher quantities get even better pricing.

How does automated and semi-automated labeling work, and what are the advantages?

Labeling machines can now be incorporated into the automated folding and bagging lines, and they can greatly increase finishing department efficiency.

Labeling garments: Typically, a worker has been required to place "size-strip" or other types of self-adhesive labels on garments before or after the folding process. This extra step slowed production speed and reduced efficiency. Now, this procedure can be automated, with the label being applied during the folding process. In some cases, the label can even be printed on demand and then applied. In either scenario, automated labeling can greatly increase the line's efficiency.

Labeling bags: As with garment labeling, a worker has often been required to place UPC, product or manufacturer brand, or other type of labels onto the bagged goods. Technology now allows this procedure to be automated, with the label being applied, or printed and then applied, as the bagged goods exit the bagging operation. There is no effect on production speed, because the labeler can run as fast as the rest of the finishing line.

Amscomatic's L-15H high-speed label applicator is designed to automatically apply labels to garments as they pass through an automatic folding machine. Positioned on the folder, the L-15H allows label placement virtually anywhere on the front of the folded garment.

The UPA-II System prints die-cut pressure-sensitive labels. It then affixes those labels to products passing by when signaled by a polarized photoelectric product sensor. It's fully automatic, and it's the perfect companion for Amscomatic's automatic bagger/sealer. Labeling software allows users to design labels with barcodes, pricing & sizing information, product branding, and a wide variety of text and graphics.

How does hand tagging compare to semi-automatic and automatic tagging?

As the tagging method of choice, hand-operated tagging guns can be found everywhere. However, they continue to present an ergonomic problem because the operator must hold three things (the tag, the garment and the gun) with only two hands. This forces compromise somewhere along the line, and reduces efficiency. The Amscomatic LLM semi-automatic tagging machine only requires the operator to place the garment in the proper position and then activate a switch, which is easier and 2-5 times faster than the alternative. These machines are also able to apply multiple tags onto to one fastener or barb, which further aids efficiency.

The PrinTagger can, in one operation, print AND apply pricing, bar coding, and other tag styles. The benefits of this machine are obvious, as it streamlines production and increases accuracy by printing only the correct number of tags for each job. Speed is limited more by the operator's efficiency than the machine's capability, but these machines can reach cycles as high as 1200 pieces per hour.

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