Tag Archives: pretreat

The “DTG vs New Car” Analogy: Production Speed

NOTE: This article comes from KatanaDTG.

Due to the inherently high cost of most Direct to Garment printers, the comparison is often made to the automotive industry.  For this comparison, we will be using the analogy of a delivery company needing to cover as many miles as possible, in the shortest amount of time (relative to a DTG print shop hoping to produce as many shirts per  hour, as quickly as possible).

SCENARIO 1: Buy one high-end supercar for $30,000 – Maintenance costs are 5 times as high and gas is a special blend which costs twice as much.  However, you never have to change your own oil or work on your own brakes – a special technician will come to you, whenever needed, to work on your car.  If you try to change your own oil, your warranty may be cancelled.  All replacement parts must come from the manufacturer.  Top cruising speed is 200 mph.


SCENARIO 2: Buy 3 low-cost cars (at $10,000 a piece) for $30,000 – Maintenance costs are very low and gas is standard unleaded at 1/2 the cost of the special blend.  However, you have to change your own oil and replace your own brakes when they wear out.  Parts wear out faster, but when they do you can purchase them at a variety of auto-parts stores for 1/5 the cost of the supercar.  Top cruising speed is 80 MPH.

With the first scenario, a business could easily cover 1,600 miles in a standard 8-hour shift, ensuring reliable operation at a significant cost.  Assuming $2 per gallon for special-blend gas (let’s pretend standard Unleaded is a reasonable $1 per gallon and for the sake of simplicity, both vehicles get the same 20 mpg mileage) they would spend around $160 in gas (or around $0.10 per mile).  Over the course of 30 working days, the fuel cost would amount to approximately $4.800 for 1,600 miles traveled.

With the second scenario, a business could easily cover 1,920 miles in a standard 8-hour shift, although more parts may need to be replaced in the process (for a fraction of the cost for similar parts of the hypothetical supercar).  Assuming $1 per gallon for special-blend gas (let’s pretend standard Unleaded is a reasonable $1 per gallon and for the sake of simplicity, both vehicles get the same 20 mpg mileage) they would spend around $96 in gas (or around $0.05 per mile).  Over the course of 30 working days, the fuel cost would amount to approximately $2,800 for 1,920 miles traveled.


Unfortunately, there is no easy answer – each hypothetical delivery company is going to have to weigh the factors which are most important to them, which may include (but are not limited to):

  • Investment / Maintenance costs
  • Cost of fuel, per mile travelled
  • Amount of “hands on” work required
  • Availability of parts
  • Redundancy considerations

When determining which model is right for your Direct to Garment printing business, be sure to properly evaluate all relevant factors – rest assured, there are options out there for virtually any business model!  Finding the RIGHT machine is far more important than finding the BEST machine…

How to Print on Wood Using DTG (Direct to Garment) Printing

NOTE: This article comes from KatanaDTG.

Printing on wood is fun and easy with most direct to garment printers.  As long as you have the ability to adequately adjust the z-axis height (the relative distance between the print head and the substrate), the process is relatively simple!


  • Blank wood panels (the ones we used are available from Hobby Lobby and other craft stores)
  • Masking tape or painters tape
  • White gesso or water based primer
  • Paint brush
  • Acrylic finishing spray to protect the printed image

STEP ONE: Wipe down each piece of wood to remove residual sawdust and other debris.

STEP TWO: Mask the outside edges of the wood with tape.

Using a low-tack masking tape, tear off small pieces and work your way around the border of the wood.  This allows you to preserve the outer bark layer, which enhances the final appearance of the printed wood.  If you are using pieces of wood without bark, you can simply tape around the outside edges to prevent runoff from the primer layer or overspray from the printing process.

STEP THREE: Coat the wood in some
sort of water based primer or white gesso.

The gesso (or primer) allows the inks to adhere properly to the wood, creating a beautiful print.  You can use any sort of white water based primer, white gesso (a common painting product artists use to coat their canvas prior to painting), or even a clear gesso if you want more of the wood grain to show through.  For this example, we used a Bob Ross brand white gesso, available from Hobby Lobby and other craft supply stores.  Allow the primer coat to fully dry, prior to moving on to the next step.

STEP FOUR: Measure the wood (we’re gonna gloss right over the myriad of joke opportunities) and set the general size of the artwork in the RIP.

Measure the width and height of each piece of wood, prior to attempting to print.  Set the width / height to ensure the printed image will cover the entire piece of wood.  This step can take some practice, as you want to ensure all critical parts of the image are printed within the boundaries of the odd-shaped wood – make sure you select each piece based on its general compatibility with the desired artwork.

STEP FIVE: Print a test image for alignment.

Tape a piece of paper (or paper towel, in our case) to the platen, lower the ink volume significantly to reduce potential bleeding, then print a test print directly on the paper.  Once the image is printed, tape the wood in the desired location, directly on top of the test print – make sure you adjust the z-axis at this point, to accommodate the thickness of the wood (once again, glossing right past that).

STEP SIX: Print your image!

SOME NOTES FOR ADJUSTING YOUR PRINT SETTINGS: We used Kothari RIP on a Katana PRO printer, so we made a series of specific adjustments to get the best results on each piece of wood:

  • Printed in high resolution, 1440 x 1440 mode

  • Changed to uni-directional printing rather than bi-directional, allowing for more flexibility on the print head height

  • Lowered the color volume to 35% to prevent bleeding

  • Added a 300 ms delay between each scan line pass, allowing more time for ink to dry

Once your image has been printed, you can remove the masking tape from around the edges of the wood – your incredible wood print is nearly done, at this point!

FINAL STEP: Apply a clear acrylic top coat to protect the printed image.

You can use almost any type of clear acrylic spray coat for this step – the point is to seal in the image, since we don’t actually heat set the ink at any point.  You can purchase various types of sealants at any art or craft store, or swing by your local hardware store and purchase a can of clear acrylic spray.


KatanaDTG MIST PT Machine – User Reviews

The Katana MIST is a highly affordable and industrial built pretreatment machine for automatic pretreat application in DTG.  The open design makes the process fast and easy, and all replacement parts are incredibly affordable!

Consistent pretreatment application and incredible speeds make this a highly useful tool for direct to garment production.

Things NOT to Do As a Brand New DTG user!

Direct to Garment printing can be exciting and rewarding, but from time to time we tend to get a little ahead of ourselves when it comes to diving in, head first.  While the process of DTG is nowhere near as complicated and fickle as it was only a few short years ago, it is still absolutely important to understand the critical learning curve you will experience as a new user in the field.

In order to ensure the greatest chances of overall success, and to avoid stumbling right out of the gate, we encourage you to consider these following bits of advice if you are currently expecting (or have recently received) your new DTG printing hardware.


  1. Booking jobs before your equipment arrives – You must understand there will be a (sometimes) long and difficult learning curve to overcome when you first start out with Direct to Garment printing.  If your machine has not even arrived yet and you are already under the gun to deliver orders to waiting clients, the stress of setup and initial training will become practically overwhelming.  We fully understand the excitement of new print processes coming into your shop, but working your way through the learning curve is going to be far more palatable if you don’t have clients breathing down your neck in the process.
  2. Refilling your own ink bags or cartridges – Refilling your own bags or cartridges can be a truly cost-saving measure, which may yield substantial savings on ink in the long run.  However, the process is fickle and requires careful control of a number of variables – at this early stage in the game, your time is better spent learning the fundamentals of your hardware as it was meant to be run, and understanding the complexity of the RIP and pretreatment processes.  In an effort to save a few bucks on your first few ink refills, you may inadvertently introduce air bubbles or contaminants into the lines which could potentially compromise the entire system.  Additionally, the manual process can be time consuming and messy, quickly negating any short-term effects.  In the beginning, stick to using the bags and cartridges filled by professionals, and work your way toward a more complex process.  You’ll thank us, later.
  3. Attempting to print complex garments – Some folks receive their DTG equipment and immediately attempt to print on long sleeves, sweatpants, blended materials and all manner of complicated garments.  Without establishing a base line standard, it is nearly impossible to gauge the true performance and quality of your machine while introducing so many different variables at such an early stage of the game.  In the beginning, stick with  high quality ringspun cotton garments with a proven track record, and work your way out from there.  In some cases, new users will spend countless hours, days and weeks trying to figure out why they can’t get a decent print, only to finally discover that the blended material they are trying to use is not properly accepting the ink or the sweatpant legs are too complicated to keep level….  Once you have a solid understanding of the basics, then you can flex your true creativity by printing on complicated garment styles and locations.
  4. Altering default printing environments without proper understanding – Understanding how your manufacturer intended the hardware to interact with their respective RIP choice is critical – too often, users jump to the conclusion that they  must be using the wrong print settings without ever exploring other variables (such as their PT process, selected garment type, etc).  This can cause new users to dive into the RIP with the intention of “making it work”, but they often create a ripple-effect of consequences which prevent them from getting back to the intended quality point.  The first step is always to ensure the basic fundamentals are in place for high quality DTG printing, then as you begin to understand the various levels of RIP control you can dive in a little deeper and truly go wild!
  5. … We will add more as they come to mind.

Being an overzealous new user can seem exciting for a moment, but may cause you to stumble on some of the most basic of fundamentals – and make no mistake about it, Direct to Garment printing is all about the fundamentals!

Of course, this is merely a simplified list and there are many more things to avoid, as a new user in the field of Direct to Garment printing.  Feel free to offer any suggestions and tips in the comments below, and we will be sure to add some of the best ones to our list!

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Rate your DTG printer! The New Consumer Reports for the DTG Industry…

Have  you been involved in DTG printing for some length of time, and want to provide your feedback for a specific DTG printer model?  We have now introduced the new Product Reviews function for DTG Print Solutions, allowing for full length, in-depth equipment reviews as well as associated follow-up rankings by the general community!

Once a review has been placed, any logged-in user can add a Comment (complete with their unique rankings for each of the provided categories) and the total product review will reflect the subsequent ratings calculation.  By adding your rating, you are contributing to a global community of DTG users with the intention of providing valuable insight and information for any potential buyers.


Whether your particular experience was good or bad, your feedback can help other users make a more informed decision in this process.  Be honest about your experiences and include any comments which could provide potentially useful information for someone contemplating the purchase of a particular piece of equipment.

Don’t see your particular printer listed?  Consider being the first to review your DTG printer (or equipment accessory) by contacting us at info@dtgprintsolutions.com – we would love to receive additional feedback from the general community, regarding DTG printers we have not been able to personally review!



A Call to Action: What Needs to Change Before DTG Printing Can become Reliable and Profitable

DTG Printing has been around for many years and it has certainly evolved quite a bit throughout the process.  In the early days of DTG, white ink printing wasn’t even possible and the general color gamut of CMYK inks was less than impressive. In a few short years, however, DTG printing has come a long way – white ink is mainstream (available on nearly every printer on the market) and the level of color output and print detail is absolutely stunning.  Visit any industry trade show across the country and you would find it incredibly difficult to not be impressed – it is not uncommon for the DTG booths to be absolutely loaded with potential buyers and interested parties, soaking up every second of the action as these high-tech wonders produce beautiful, full color prints on garments with what appears to be relative ease. Why then, do so many companies that adopt DTG printing wind up selling their machines within months of purchasing them (or sometimes, if they really like the abuse, they might keep battling their printers for a year or longer before they inevitably jump ship), often at a huge financial loss?  Part of the answer is staring us in the face while we stand there at the trade show, mesmerized by the visual print quality of the garment – the prints are just so incredible that we feel there is no way we can’t make money selling them!  Most of us would be hard pressed to find a screen printer would could even come close to competing with this level of quality.  However, what we often fail to notice is how excruciatingly long it takes to create a finished product, and they aren’t even showing all the steps at the trade shows!! Along these lines, I have compiled a simple list to explain what I feel must change in the DTG printing industry, before it can ever be accepted as a truly mainstream process.  After all, if small business owners can’t actually make money on it, then what’s the point??

DISCLAIMER: I am well aware that there are people out there having success in the DTG market.  These successful individuals are often the exception, rather than the rule.  I have noticed that people on the East coast seem to have slightly fewer issues with production (possibly due to higher overall humidity levels) but overall, more people fail out of DTG than are successful in the long run.  This article is meant to address the issues faced by most people who engage in the fine art of DTG printing, regardless of which printer they have selected.



To print in the highest quality settings using most standard 4880 based DTG printers (which, regardless of what the salespeople tell you, is virtually mandatory if you want to achieve the same level of quality you see at the shows) on a dark garment, assuming a standard sized print area (approximately 12″ x 12″), it could easily take 10 minutes per garment to complete the actual printing process!  While this does not include the time required to pre-treat each shirt prior to printing, it is important to remember that you will have plenty of time to perform this step while the machine is doing its thing….  In theory, the initial pretreatment process shouldn’t add any time to the overall process, just more labor – that is, unless you are one of those shops who pre-treats shirts prior to printing them (rather than doing it simultaneously with the print process). At approximately 6 units per hour for high-quality DTG printing, how can anybody really make a profit?  Dark garments are, as one might imagine, the most popular type of garment for most clients – you can try to talk them into white shirts (which are much easier to print, faster, cheaper, etc) but you can’t build a strong foundation if you are constantly trying to talk people into the “easier” option for you….  Sure, light garments (ie, no white ink underbase) are better for us as printers, but your potential clients really don’t care how much effort, time or money you put into the finished product – at the end of the day, they all want it cheap and they want it fast! Of course, some machines are faster than others, but I have personally owned everything from the Kornit to a multitude of Epson-based DTG printers in the last 10 years and the best I have been able to get in a real production environment, thus far, was about 12 units per hour on dark garments (and I was not entirely satisfied with the print quality, at those speeds).  Advancements in technology have allowed some companies to develop printers using larger, more industrial print heads – Ricoh is a common choice among manufacturers, but using larger print heads to lay down more ink in a shorter period of time can often compromise the overall print quality, since tiny droplets of ink are critical to creating to most subtle details and effects (just ask Anajet how that worked out for them).

Until we get to a point where the average DTG printer is capable of producing at least 24 units per hour (dark garments, at a standard print size), I don’t see most people being able to make a decent profit – especially when compared to many other print decoration options available which are faster and less expensive.

NOTE: You can approach DTG from the perspective of an embroidery business model – since each machine can only produce a painfully limited number of units per hour, it makes sense that you could scale your business appropriately by adding additional machines…  The problem with this, of course, is you wind up dealing with a multitude greater level of tech support and troubleshooting, so the scale factor is not easy to calculate.  Additionally, since the cost of each unit is general $15,000 or more, it would require an investment of about $150,000 to hit an hourly production rate of about 60 units per hour on dark garments – in the real world, you will always have a certain number of machines which are “acting up” at any given time, so really you wouldn’t even hit those numbers most of the time (even for such a staggering investment).


In the world of custom printed t-shirts, everyone is trying to save a buck.  Each and every client seems to want everything for nothing, so there is not much room for margins (especially when the client is ordering anything other than a single unit).  This becomes a major issue, of course, when you can only print 6-12 units per hour (which means you must amortize the cost of your general overhead and labor across a minimal number of finished product) and the cost of ink “per print” is often in the range of $2-3.  For the record, that number doesn’t even include the cost of the pretreatment, which must be added to the garment prior to printing. At one point my shop had 3 Neoflex DTG printers, which produced the absolute best quality at the time (compared directly to all the other models and brands I have owned) – since these 4880-based units we capable of producing some pretty big prints, we had lots of clients coming through the doors to take advantage of our print size capability.  While we were excited at first, our emotions soon turned to disappointment as we found the average cost of ink “per shirt” for these larger prints (generally 16″ x 20″) was easily averaging $8-10 per print!!  Oh, and at that particular print size (at the highest print quality) the total print time “per garment” was about 22-24 minutes.  At that rate and at those prices (assuming we had ZERO other expenses to contend with, aside from labor) we would have had to be charging around $34 per shirt to make our relatively low “net profit target” of $60 per hour. Of course, this would not have taken into consideration any misprints, quality rejects, shop overhead (like rent, electrical, phone and internet, etc) – the true number would have been north of $40 per garment, for a typical t-shirt…..  I suppose some markets do exist which would support this price for unique, one-off custom garments, but that market doesn’t include the clients that most of us tend to service on a regular basis.  If you can charge that much for a shirt, then more power to you!  We were trying to be competitive wholesale DTG providers, and it simply wasn’t feasible at those prices.  In fact, it was outright laughable.

In order for the average print shop to become competitive and profitable with DTG printing, the average cost “per print” really needs to fall in the .50-$1.50 range for an average size print on a dark garment.

NOTE: Many salespeople will try to tell you that their average cost “per print” is incredibly low – Brother even records print cost data across a broad range of users, allowing them to determine an allegedly accurate number for use in their sales and marketing documents.  However, these numbers generally include the cost of ink for small images (like left chest prints) as well as light garments – after all, it is a “total average” not a specific average…  At the end of the day, this is incredibly misleading since we must base our pricing on what it costs to do a standard size print – our profits don’t work in averages…. They work on a “per job” basis!


The production rates and ink costs provided assume that the DTG machine is actually working properly, without fail – in the real world (and I cannot emphasize this enough), I have never owned a DTG printer that actually worked all the time!  In fact, I don’t think it is uncommon to spend upwards of 30% of your time, on average, maintaining and troubleshooting your investment. Some companies offer excellent tech support service, while others tend to leave you high and dry after you make the purchase – even with excellent tech support, you will never receive the full-time, hands on assistance that most shops need in order to keep these machines running at peak performance, all the time.  Most DTG printer owners find themselves overnighting parts at an alarming rate, and spending as much time with their printers “opened up and in pieces” than actually printing garments for their clients…  Many issues are fairly common and don’t take too long to resolve, but this does not excuse the fact that DTG printers simply require significantly more maintenance and downtime than any other printing method or equipment I have ever seen.  Maybe 3D printing is the same way, but that is literally the only comparison I can make at this point in the game. When my shop finally stepped away (for now) from DTG printing, we had 5 DTG machines from different companies, as well as our own in-house tech support team dedicated to keeping them running.  Our main tech had been involved with many of the DTG printers we had owned, spent countless hours replacing parts and fixing major and minor issues, and had a solid working relationship with the primary tech support guys at the various manufacturers who had provided our equipment.  At the end of our run, there was not enough money I could possibly offer him to stay around and help me continue fixing my machines – he actually told me it was like trying to nail Jello to a tree, and he was “done with it”. A single Epson print head can cost between $400-700, depending on which model of printer you own (for the Ricoh, Brother and Spectra based machines, the cost is sometimes $1,000-4,000 per print head) – considering how shockingly easy it can be to destroy a print head (either through continuous use or by improper maintenance), this is a serious cost that must be considered in the long run.  This, of course, doesn’t take into account replacement capping stations, wiper blades, encoder strips, worn down plastic pieces, ink lines and lots more).

NOTE: I have owned at least 14 DTG printers in the last 10 years, and there has not been one single unit which has not required me to replace the print heads at least once!  This includes the supposedly “perfect” Brother GT-541 and the Kornit 932, as well as all other Epson based printers that have found their way through my shop over the years.  The inks we are running through these things have a much higher viscosity level than what the Epson print heads were designed for, and even the more industrial heads are subject to wear and tear from the TiO2 pigment that is added to the white inks to give them their opacity.  Additionally, all print heads are prone to drying out when they are not used regularly, so don’t even think about letting your investment sit idle – not even for a day!

Browse this website and you will find countless images from the last ten years, showing every single printer literally turned inside out and in various stages of disrepair – we are not unfamiliar with the technology and our issues cannot (to the dismay of so many salespeople, tech support people and equipment manufacturers) be simply attributed to fundamental “user error” – although this is the most common message you will hear in this industry, we cannot accept that we are the problem and the machines are so awesome….  That concept simply does not mesh with reality. Consider this – major companies such as CafePress and Zazzle are famous for their large, streamlined facilities and overall success in the industry; despite this, anyone behind-the-scenes will readily acknowledge the fact that at any given point, a certain percentage of their manufacturing stable is inoperable or receiving maintenance (scheduled or otherwise).  There is an overwhelmingly high amount of equipment turnover with larger DTG printing companies, whereas they will often invest huge sums of money into large numbers of new printers in an ongoing effort to find the “best machine out there”.  If these companies were completely satisfied with their chosen machines, we wouldn’t see them constantly switching between different brands.  Of course, I know they all have a certain number of reliable units which establish their “base foundation”, but having been on the sales side and having discussed various aspects of the technology with some of the big wigs in these companies, I can say with certainty that they are not completely content with any of the machines they are using.

If the DTG manufacturers want small business owners to succeed, they will design these machines to operate with minimal maintenance for much longer periods of time.  Even with OEM inks, most Epson printers are not intended to be printing constantly, so adding thicker ink to the equation isn’t doing us any favors in terms of reliability.  I should not have to do more than 10 minutes of maintenance per day (at most!) and there should be very little downtime on my DTG printers….  Additionally, I should be able to leave my printer idle for 2-3 days without worrying about whether I just cost myself $700 in a damaged print head.


Understand, I am not a “DTG hater” – in fact, I am probably one of the greatest supporters of this technology, having been involved since the very early days in a very public way and invested huge sums of my own money (as well as various investment capital) into trying to make it work in the real world.  When one machine didn’t hold up to expectations and hype, I tried the next in line, and so on until I finally couldn’t justify it any longer.  I am not beholden to any manufacturer or brand, and although I have many long standing relationships and close friendships within this industry, the primary purpose for my involvement is my own success in this niche and I would never continue to own a machine that was not truly making me money.  I want DTG printing to work in the real world, and I want to stop hearing stories about people who have invested their life savings into this business, only to be disappointed in the end. For now, I find myself licking my wounds and settling old accounts to try and recover the pieces from a long, difficult journey into this technology – having adopted several different processes which don’t involve DTG (dye sublimation being my favorite, so far), I am slowly rebuilding and getting things back on track.  As the industry continues to develop and grow, I find myself checking in constantly to see what the “next big thing” is, hoping and praying that we are getting closer to something that can be widely adopted (and retained) by the average business owner.  I expect that, at some point, I will be totally impressed and awe-struck at how far the industry has come, and I will take another stab at in-house DTG printing. Until then, however, I would like to offer an open challenge to all DTG equipment manufacturers out there:

We as a consumer base need more from you.  We need you to consider the points laid out in this article and we need to see some tangible progression in this industry.  Distributors are making a killing off of equipment sales commissions and ongoing ink sales, but the end user is often left disappointed and broke.  We cannot tolerate 6-12 unit per hour print speeds, and we certainly cannot shoulder the burden of $3-10 in ink for a single print – large sized prints should cost us about $3-5 in ink, max (with decent coverage).  Standard sized images, on dark garment, should use between .50-$1.50 in ink.  During a normal shift, while also considering any possible downtime and whatnot, we should be able to print 24-36 garments per hour on a single machine – anything less makes this more of a hobby than a serious business.  Finally, although we understand that there is only so much you can do about the cost of parts and whatnot, it is really important that our printers are able to function for an entire day without requiring us to do any heavy maintenance.  In fact, we really shouldn’t be opening up our machines (beyond opening the lid for a quick cleaning) more than once every few weeks (or months).  We don’t want to be constantly replacing parts, and although we love understanding every aspect of our machines we would rather not have to be certified experts and replace parts on a seemingly regular basis – we don’t have to deal with that sort of thing from our wide format printers / plotters, or from our dye sublimation equipment, so why should we have to put up with it for DTG?  If things still aren’t completely up to par, be honest about it – don’t tell us to expect 15 prints per hour, when we both know we should probably expect more like 6-8…  At the end of the day, it will help us better determine if this business is really for us, and if we choose to dive in then we can at least prepare for what is in store for us and create a business model that is appropriate for this process.  DTG printing has come a long way and we are pleased by this, but there are still too many people losing their asses after a relatively short period of time trying to make it work.  Don’t just promise us more, but deliver more – actions speak louder than words, and we can’t wait to see this technology evolve into something entirely practical and profitable.

PS – Oh, and don’t try to pull that nonsense about how “when it becomes too easy, everybody including Wal-Mart will be doing it” – dye sublimation is easy, as is standard vinyl printing and plotting (relatively so, of course)…  However, we don’t see them destroying the small business market in these other fields – sure, there will always be big corporate competition, but that doesn’t mean we can’t be just as competitive with some reliable and affordable equipment and inks.

If you agree with this, please comment or share this article!  We are spending a lot of money to help develop this industry, so we should definitely be getting more out of it, at this point.  The important people are reading it, and the more attention we can give (and support), the more likely they will be to take it seriously.  Don’t be content acting as a paying guinea pig for the equipment manufacturers – demand more from this industry, so we can all get more out of it.

Nonstop Neoflex Production – One Hour in 15 Minutes

Many people ask us about the potential production rates they can expect with their DTG printer…. While the answer to this question may be difficult to pinpoint without understanding your machine capabilities, intended print resolution, production setup and other factors, we can at least show you a one-hour snippet of production from our very own DTG production facility.  This video was released awhile ago, but it shows a full one-hour production cycle, uninterrupted, including the entire pretreat / print / heat press cycle.

This video shows only one employee working on production (me) using on only one of our DTG printers, and is sped up to 4x normal speed to ensure you don’t get too bored during the process…  We are using the following production setup for this video:

  • PRINTER: Neoflex DTG printing system by All American MFG (based in Philly, PA)
  • RIP: Kothari DTG RIP (branded as NeoRIP PRO)
  • PRETREATMENT: ViperONE Automatic Pretreatment machine
  • PRINT SETTINGS: As always, we are printing in Hi-Resolution mode (the only mode we feel comfortable offering to clients for top-quality DTG printing)
  • GARMENT COLOR: We are printing on dark garments, using the full three platen setup available on the Neoflex DTG printers

Average production speeds (with our configuration) are approximately 6 finished garments per hour on one machine.

FREE Articles for YOUR Website!

We are happy to announce that we are making many of our most popular blog posts (from our printing company website) available to the general public for use on any website.  If you are involved in the Direct to Garment (DTG) Printing business, it helps to offer your potential customers as much information as possible.  By addressing their concerns early, you will be able to avoid many potential miscommunications with your clients during the actual order process.

Feel free to use the FREE resources available on this website, including the FREE Articles for YOUR Website list to enhance your own customer experience for your DTG printing company.

Over the decade we have been running our DTG printing business, we have developed a number of articles which help better explain certain facets of the business to new clients.  For your convenience, we are making some of these articles available to you, for your website – feel free to copy the articles and paste them on your own website to help further educate your customers.  All articles listed below are available to use and edit as you see fit – please let us know if you have any questions.

INSTRUCTIONS: Start by copying and pasting the text of your selected article to your own website.  Once you have pasted the text, be sure you replace all of the company name and contact information with your own, and carefully review each article to adjust pricing examples and other information to fit your own business model.  Don’t be afraid to make some changes!

NOTE: Your are free to use the text from these articles as you see fit, but the images are copyrighted material and may not be reused without our express written consent.  Please show your customers what you are capable of producing by printing and photographing your own custom products to go along with these articles.  The images currently presented represent our efforts and hard work, and it is important to show off what you can do. 

Aside from that, have fun with it!  These articles should give you a good starting point when building your DTG printing website, and will allow you to more thoroughly cover your back-end when people take issue with certain caveats of Direct to Garment Printing.


We hope you enjoy these free articles to help jump start your own independent DTG printing website – if you have any questions or comments, feel free to contact us or make a comment at the bottom of THIS PAGE!

More great articles will be coming soon, so check back frequently to ensure you have all of the most up-to-date information for your company website!

Top 10 Reasons NOT to Get Into DTG Printing

Direct-to-Garment (DTG) printing can be incredibly rewarding, and offers many advantages over traditional screen printing.  Whether you are a new startup company or an established print shop looking to augment your production capabilities, DTG is definitely worth a second look.  However, it is important to note that DTG printing is not for everybody; due to the particular challenges that it creates, you must be prepared to commit yourself to understanding every facet before you can hope to have a relatively trouble-free experience.  Here are 10 good reasons to consider avoiding DTG printing, for the moment:

1. Printing Environment Must be Carefully Controlled

The physical properties of the water-based inks are incredibly sensitive, changing drastically based on the external environmental conditions.  For instance if the air in your print room is too hot or dry, the ink will quickly dry in the print head causing nozzle blockage and other related issues; this can manifest in moderate to severe banding (missing or rough lines in the printed image) or even entire nozzles dropping out.  Especially in areas with more extreme weather (for instance, Southern California tends to be very hot and dry), steps must be taken to keep the environment cool, humid and comfortable.  An ideal operating environment would have the temperature somewhere in the general range of 75-80 degrees and a relative humidity level of somewhere between 30-60% – depending on where you are located and what kind of building you are in, you’re going to have to look into various humidification systems, air conditioning, swamp coolers, etc.  This is not the type of equipment you can randomly add to your warehouse work space without seriously considering whether or not it will be protected from the extreme elements.

2. Equipment / Consumables are Expensive

Getting into DTG printing can represent a huge financial risk for a small business on the edge; with many DTG printers averaging around $20,000, you can easily wind up spending $25-$30,000 for an entire package (complete with printer, pre-treatment machine, heat press, supplies, shipping, training, etc).  If you are confident that this is the route for you, try going to a few trade shows and keep your eyes out for a great deal – trade shows are the best place to save money on the initial equipment purchase.  However, once your machine arrives, there isn’t much you can currently do about the ongoing costs of the ink and supplies; on many machines the cost of ink “per print” can easily be in the $1-3 range for a standard size print on dark shirts and the cost of pre-treat fluid can easily cost another .30-.80 per print – compare that to the cost of plastisol ink, which often ranges from .05-.15 per print!  On machines that accommodate larger print areas, the cost of ink alone can actually get up to $4-8 depending on size and coverage.  Unfortunately, the cost of ink does not come down in larger quantities, so there isn’t much we can do (as DTG print shop owners) to compete with screen printing prices on larger quantity orders – there is almost always a break-even point where screen printing still makes more sense than DTG, and it is important to recognize this distinction and not try to make a decoration technique work for an order that does not call for it (for example, 50 black t-shirts with a white ink print on the front would be better suited for screen printing rather than DTG).

3. The Process is Painfully SLOW

While we are able to skip the majority of the setup and tear-down process, screen printers have a huge advantage when the ink actually hits the t-shirt; screen printing presses (even the manual variety) are considerably quicker when it comes to actually printing, whereas the process on a DTG printer can take quite some time.  Although white shirts are relatively quick (its not uncommon to knock out 20-50 white shirts per hour, depending on your particular equipment, setup and print resolution), dark shirt printing can be the bane of any DTG print business – realistically, expect to print about 8-15 black shirts per hour under normal circumstances.  The number of prints you get per hour is directly related to the specific print resolution you operate at, so the higher quality you are looking for, the fewer prints per hour you will be able to achieve; printing at the highest resolution on the Neoflex, there are times when oversize images (15″ x 20″ dimensions) are coming off the machine at a rate of about 3 prints per hour….  You need to enter into this business with a practical, realistic view of how long it is going to take you to print some of the more extreme orders – without this realistic understanding, you might price yourself out of business before you even get started (Need help understanding how to properly price DTG printing services?  Learn about our free tools, here).

4. No Minimum Orders

Wait a minute…. Didn’t this same point make an appearance on our list of top 10 reasons to get involved with DTG printing??  Why then, would it also show up on a list of reasons why NOT to get involved with DTG printing?  The answer, while simple, is often overlooked; although it is great to have the ability to print “on demand” for your customers with no minimum order quantity, it is also overwhelming to take the time out of your busy day to educate a client, find out what they are looking for, then hold their hand throughout the entire process for them to only order a single custom shirt – the harsh reality that many small business owners run into is that it can be very difficult to maintain profitability when you are spending an average of 45 minutes per client and each person is only ordering one or two shirts!  The best way to avoid this unfortunate situation is to streamline your ordering process as much as possible, through the use of online design software and other technology to minimize the amount of time spent processing each order – also, try providing as much detailed information as possible for your clients, allowing them to seek out answers on their own either through your website or other provided documentation.  The fewer times you have to repeat answers to simple questions, the more profitable your business will be!

5. Garment Selection is More Critical than Most Other Processes

DTG printing is not intended to be used on all garment types; in fact, the inks tend to work best when applied to 100% cotton, so it is best to avoid 50/50 blends and other non-cotton fabrics as much as possible.  On top of that, it is important to remember that not all cotton is created equal – you will experience better print quality and more consistent wash fastness when you select garments that are woven from higher quality ring spun cotton (30/1 weave is ideal).  All individual brands, styles and colors can potentially produce varying results of quality and wash-fastness, therefore it becomes critical that you thoroughly evaluate any potential blank garments that you want to print on.  It can get even more confusing when you begin tracking where each batch of shirts was manufactured, as different countries of origin can produce drastically different results, even when the brand / style / color are identical!  Once you’ve found blank garments that print well and are consistently meeting your quality expectations, try to stick with them and encourage your clients to do the same; even if you warn a client that 50/50 blends won’t print as well, they will still insist that you do it and then become indignant when the results are sub-par.  As a DTG printer, it is recommended that you think long and hard about a company policy that indemnifies you of all responsibility for client-supplied blanks (if your company even accepts client-supplies blanks), since you cannot properly vet products that you have not thoroughly evaluated.  Or, even better, simply avoid accepting client garments altogether and focus on blanks that provide the highest possible quality – this is the only way to properly protect your reputation down the road.


Use High Quality Wooster Brushes to Help Minimize Fibrillation

DTG printing can produce some pretty incredible full-color prints, but one thing that can really ruin the overall appearance of any print (no matter how vibrant or beautiful the image may be) is fibrillation – those annoying little fibers that always seem to pop up through the ink, causing an otherwise great looking print to look rough or patchy.  No matter what ink / pre-treatment combination you use or which DTG printer you print with, the problem exists across the board.  Of course, selecting the proper garments for DTG printing can go a long way to help reduce this problem (look for garments with a smoother print surface; blanks that have been treated with an enzyme wash are a great place to start) but there are additional steps you can take to help reduce this problem – brushing the shirt after pre-treating is perhaps one of the easiest and most effective of these, and choosing the proper tool is vital.

The purpose of brushing the garments is two-fold:

  1. Better Pretreat Coverage: By brushing the entire printable area after spraying, you spread the pretreat fluid around and ensure more consistent penetration.
  2. Push Down Garment Fibers: By applying consistent pressure while brushing in smooth, consistent strokes, the fibers of the garments are pushed down creating a smoother, more even print surface.

When we started printing white ink with DTG, we evaluated a wide variety of foam brushes, rollers, etc – although these worked modestly well for spreading the pretreat fluid evenly across the print area, our experience showed us that the porous foam brushes seem to pull the fibers up more than they push them down, thus negating the effect and doing little to prevent fibrillation.

At some point it was recommended to us to try using premium Wooster brand brushes instead of foam rollers / brushes, so we invested a few bucks in a (6) pack of 4″ wide brushes and we haven’t looked back since.  These brushes are perfect for use after spraying the pretreat fluid on the garment, and they do a much better job of pressing the fibers down onto the garment (without lifting them back up in the process).  We strongly recommend giving these brushes a try if you are involved in DTG printing, especially if you are experiencing trouble with fibrillation in the final printed garment.

The specific brushes we use are available online, but for convenience we have added them to the Amazon widget toward the top of this page!