Few things are more frustrating than stopping production because ink keeps clogging the screen. Clogged mesh slows production and causes poor print quality.

At One Stroke Inks, we help printers troubleshoot this issue regularly. Most screen clogging problems come from a handful of common causes, and they're usually easy to fix.

What Causes Screens To Clog?

Screen mesh becomes clogged when ink or contaminants block the openings that allow ink to pass through.

Common causes include:

Finding the root cause is the first step toward fixing the problem.

Ink Buildup During Long Runs

Certain series of inks have different intended uses. There are two categories of inks, general purpose inks and high performance inks. What they are designed to do requires a particular viscosity. Choose the correct series to reduce buildup on long runs.

General purpose inks are meant for light cotton and blends. They have a lower viscosity, are easier to print without flashing, and build up far less on the back of the screen than a high performance ink. For the best wet-on-wet printing experience, consider adding WOW additive to our 480 Series. This viscosity is not meant to cover dark fibers.

High performance inks like the Hybrid Series are meant for dark cotton and blends. A higher viscosity helps the ink cover dark fibers without having so many layers that the print becomes bulky. This thicker viscosity is more prone to build up and requires flashing between each color.

Understanding how viscosity changes the way ink behaves in the screen and on the garment can help shops improve production and the quality of their prints

Improper Screen Cleaning

Old emulsion residue, dried ink, lint, and tape adhesive can all restrict ink flow. Even small contaminants trapped in the mesh can create pinholes or clogged areas. Proper reclaiming and degreasing help maintain clean mesh and improve print quality.

Products such as Franmar D-Grease, Franmar Strip-E-Doo, and Saatichem Remove ER5 help.

Mesh Count Matters

Using a mesh count that is too high for the ink deposit can create printing problems.

For example, trying to force heavy white ink through very fine mesh may lead to poor ink transfer and mesh clogging.

Lower mesh counts generally work better for white inks and thicker deposits, while higher mesh counts are ideal for fine detail and thinner inks.

Ink May Be Too Thick

Heavy-bodied fluorescent inks and white inks have higher viscosities. If the ink is too thick, it can begin filling the mesh openings and not flowing through them properly.

High-opacity inks such as #26 HV White and Highlighter Series are designed for strong coverage, but proper mesh selection and printing technique are still important. It is perfectly acceptable to use higher mesh counts than recommended. However, this might require a viscosity adjustment in order for the ink to flow through the mesh easily.

If needed, additives such as Auto Formula Additive can help improve flow characteristics.

Heat Affects Printing

Low temperature inks usually cure around 250°F. They begin to gel at a much lower temperature when compared to high temperature inks. This can cause the ink to gum up in the screen.

Temperature controlled shops struggle with heat just as much as garage printers. Dryers, flash units, and heat presses all produce residual heat. Take the time to make adjustments on your machinery to accommodate a low cure ink. Do not assume the same settings for a high temperature ink will work.

How To Prevent Screen Clogging

Most clogging problems can be reduced by following a few simple practices:

Good Screens Start With Good Habits

Most screen clogging problems come down to technique, environment, or maintenance rather than defective ink.

At One Stroke Inks, we help printers solve these issues every day. With the proper mesh, clean screens, and the right ink for the application, you can spend less time cleaning screens and more time producing quality prints.