White Speckles on the Garment
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- Doris Horton
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1 GT DIGITAL GARMENT For Technical Assistance Please Call Toll Free BROTHER White Speckles on the Garment White speckles on the garment may appear in three ways: On areas of the garment where there is no printing in the form of droplets. On the print area, mainly noticeable in the cyan ink, before curing the ink. On the print area, mainly noticeable in the cyan and magenta ink, after curing the ink. White ink droplets on areas where there should be no printing When the white droplets appear on the garment where there should be no ink, it is due to debris hanging down from the nozzle plates on the white print heads. This debris or hair-like residue usually develop
2 from the white ink and debris being pushed by the wiper into the wiper cleaner cartridge. These hairs will collect around the edges of the nozzle plates when the wiper cleans the nozzle plate surface. White ink contains Titanium Dioxide. This provides the vibrancy to the ink. This also makes the white ink heavier than the CMYK inks. When the wiper clears the coating of ink remaining on the nozzle plates from the previous print, it will collect on the hairs around the nozzle plates if the hairs are present. As more ink collects on the hairs the droplets will be flung off during the carriage movement while it is printing. The droplets come off usually when the carriage changes direction. That s why the droplets are on areas where there is no print. If the white cap rubbers are dirty it will be likely that the print head nozzle plates will have the same debris around them.
3 The previous picture of the underside of the white print heads shows where debris and hair-like fibers have collected around the edge of the nozzle plates. To clean the nozzle plates, eject the platen tray and remove the platen. Send the tray back into the printer. Program a Nozzle Cleaning via the Maintenance menu. Power off the printer when prompted. Open the top lid and move the carriage to the center. Remove the wiper Cleaner Cassettes and place them aside. If they are oversaturated be sure to replace them before powering on. Take note how the wiper blades are in the center and almost making contact with each other. It is OK to move the wipers to have better access to the caps but they MUST be returned to the center position before inserting the wiper cartridges, closing the lid and powering on the printer. Examine the white cap rubbers and wiper blade. If debris has built up around the perimeter or inside the cap it will have to be removed. It is very important that no debris falls into the drain/suction hole or the capping tube will be clogged and restrict ink flow. Below are examples of dirty cap rubbers and nozzle plates. Push the carriage to the center of the machine for better access to the cap rubbers and the underside of the print heads. Be sure to move the carriage by pushing on the left or right vertical support as needed. Moisten a swab with wash solution and clear the debris. You may want to let the wash solution stay on the caps for a minute to let the ink breakdown and then swab the debris away.
4 Clean the debris from around the edges of the caps. Wipe the swab on a lint free cloth so it can be reused during this process. Take extra care not to let any debris fall into the cap rubber suction hole, otherwise the capping tube will clog. You may use a lint free cloth and the swab to clean around the sides of the cap. Be sure to clear all hair-like fibers. Be sure the edges of the white caps are clean. It is OK for white ink to be in the cap. The weekly white tube cleaning will keep any build from occurring. Swab the front and back edge of the wiper blade as well. Use a lint free cloth if that is easier. Remove all hair-like fibers. Swabbing the wiper and letting the solution sit for a few minutes will make it easier to wipe away the dried ink residue. Check the edge of the wiper for any cuts or unusual wear. The wiper blade should be changed if it is damaged. Once the caps and wipers are clean you will need to clean around the edges of the white nozzle plates. Push the carriage so it is in the center of the platen area. Moisten a swab and clean the underside of the print head. Wipe any debris away from the center of the nozzle plate toward the edges. Wipe debris from the swab onto a lint free cloth and moisten the swab with wash solution and continue cleaning the nozzle plates until all residue has been cleared.
5 Take care not to pull on the edges of the nozzle plates or you may separate it from the print head. That will cause irreparable harm to the print head. You will likely have to swab on the immediate side areas above the nozzle plates to remove all of the hair-like fibers that cause the ink droplets. Once all areas have been cleaned be certain the wipers are in the center position. Insert the wiper cleaner cartridges. Place several drops of wash solution in each cap rubber. Close the lid and power on the machine. Once the machine has completed the boot process, perform a powerful cleaning on each head that you swabbed. Wash solution likely entered the nozzles and must be pushed out by the head cleaning process. Perform a nozzle check on all heads and perform head cleanings as needed to achieve all nozzles firing. White Speckles on the garment in the print area before the ink has been cured A smooth print surface will produce a quality print. Consider printing a photograph on glossy paper, the image quality is excellent. If you were to print the same image on a piece of construction paper the print quality would be very coarse. When lint and excessive fibers are present on the print surface this debris will become more pronounced when ink is sprayed upon it and the resulting print quality will be greatly reduced.
6 Higher quality cotton garments are Ring Spun or Combed. 100% cotton without any special processing, carded open end, will be much more fiberous. This will reduce the print quality. This image shows that there was a build-up of lint on the garment before printing. This image was taken before the ink was cured. Using a higher quality cotton fabric will greatly reduce the likelihood of this type of build-up on the garment. Carded Open End cotton fabric VS Combed or Ring Spun Cotton
7 These images above, by Bella + Canvas, show how the quality of a print can differ when a higher quality cotton fabric is used. To cure the Brother pretreatment solution properly, it must be cured on a heat press at 356 degrees F for 35 seconds with 80 pounds of pressure. A Teflon surface must be between the pretreated garment and the heat press element during the curing process. The high pressure during the curing process not only bonds the solution into the fibers of the fabric but help flatten the fibers. This helps create a smooth print surface. Once the pretreatment has been cured, the fabric should not be shaken out to make it easier to slide onto the printer platen. This will make the fibers pop up. If the cured pretreated garment is not printed on the same day it was pretreated, moisture will be absorbed by the garment. This will cause the fibers to rise. The garment does not need to be pretreated again, only pressed to remove the moisture and flatten the fibers again. If you are in an environment with high humidity the garment will absorb moisture very quickly so you may have to press the garment after several hours. You should not use a lint roller on a pretreated garment. This will not only pull up the fibers of the garment but likely remove some of the pretreatment. This will also cause inconsistent vibrancy throughout the print due to the removal of some of the pretreatment in areas.
8 If the garment does have a noticeable amount of lint, it is recommended that the lint roller be used before applying pretreatment to the fabric. If you do use a lint roller you should press the fabric at 80 pounds of pressure before applying the pretreat solution. If lint or fibers are noticeable on the pretreated garment BEFORE it is cured, you may use a fine bristled brush to brush with the weave of the fabric. You should only brush in one direction. Never use a lint brush in this situation. A brush manufacturer such as Wooster produces several types of brushes that will perform well. A rough fabric surface can also be caused by a soft/spongy press surface. If the fabric is compressed with different areas of pressure the fabric will shift and rub. This will cause the fibers to pull up through the pretreatment film before it was cured. Fitted Teflon sheets on the top and bottom plates will help provide a consistent compression of the fabric when the press is locked down on the fabric. The manufacturer of your press should be able to provide you with the proper fitted Teflon covers. White Speckles on the printed area after curing the printed Garment When the quality of a printed garment is good after the print on the garment has just been completed, and the garment is still on the printer platen then the pretreatment application, the artwork editing, the print driver settings, and print operation have likely been performed properly. The only step left to complete the DTG operation is curing the ink. White speckles appearing through the ink after the ink curing process can only occur when the curing is done by a heat press. The white speckles are actually the cotton fibers being pulled up through the ink. The fibers pass through the base layer of white ink. This is why the speckles are white. Most operators place a sheet of parchment paper over the printed surface to achieve a matted look instead of a glossy finish. If a clean Teflon sheet is used instead a glossier look will result. Reasons for the fibers to pop through are: Low curing temperature Low curing time
9 Contaminated curing surface Too high of a pressure applied during the ink curing process High white ink values applied Wrong type of covering (parchment paper type) placed on the uncured garment Inconsistent heat press base soft spongy foam base surface Improper Pretreatment application (amount/grams) Double printing applied (white +color) These causes will not be possible when a printed garment is cured in a conveyor drier. However the recommended belt temperature, 320 F, and the garment time in the dryer, 3 minutes and 30 seconds, are required so the washability of the garment will be acceptable. Please use the following steps to remedy each possible listed cause for heat press related causes. Low Curing Temperature The required temperature to cure the ink is 356 F (180 C). The temperature of the heat press will drop after each use and it may take several minutes for the temperature to recover. Because of the large amount of manufacturers and models there will be various times for a heat press to return to the desired temperature. Another possibility is a heat press may not be calibrated correctly. Even though the temperature display may indicate the desired temperature, there is no guarantee that the press is actually at the indicated temperature. An infrared thermal gun or a probe may need to be used to test the surface. If there is a fitted Teflon cover over the element the probe should be used as the infrared gun will be reading the temperature of the Teflon covering which will likely be separated from the element plate when it is in the open position. Thermal strips may be used for testing purposes however most indicate in 20 degree increments. Take care when ordering thermal strips as there are many temperature ranges available to test for a specific temperature. If the temperature is too low the ink may seem dry to the touch but the parchment paper may not peel away cleanly. If the parchment paper pulls on the fabric as it is removed, it will pull up the fibers as well. The fibers will pass through the white ink layer first. That is why the speckles are white. These speckles are very noticeable in a cyan field and to some extent a magenta field. Less white ink is laid down under black ink. That is why the white speckles are not that prominent in very dark backgrounds. Low Curing Time The required curing time is 35 seconds. That is the amount of time needed, in conjunction with the proper temperature, to remove the water from the ink and have the white ink bond to the pretreatment solution and for the CMYK ink to bond to the white ink. If too little time has passed the same issues with too low of a temperature will occur. Take note when the timer begins as you lower the heat press. If you lower the top plate and let it hover, the timer may begin on some models. On some pneumatic models the timer starts as soon as the activation buttons are pressed but full contact may not be achieved until 2 or 3 seconds have passed. Adjust the timer to compensate for the missed contact time on the garment. 37 or 38 seconds may be required for some models.
10 If a high amount of white ink is used (Highlight and Mask values) the ink may be slightly pasty so when parchment paper makes contact with the ink some sort of bond may occur. In situations like this you may have to let the heating element hover over the garment for 30 seconds before placing the parchment paper over the garment and locking down the heat press. Contaminated Curing Surface The curing surface of the pretreatment solution and ink should never be shared. The pretreatment solution will leave a sticky residue on the Teflon covering. If this surface makes contact with the print surface it will ruin the print. The Teflon surface should be cleaned after curing pretreated garments for the day. If parchment paper is used when curing the print keep in mind that the parchment paper will eventually lose the ability to separate from the cured print cleanly after several uses. Lower quality parchment paper may last only once or not at all. This link is for a brand that has been used successfully: Silicone/dp/B00C7KUBR8?SubscriptionId=AKIAIQWHH4HRPK7LRQTQ&camp=2025&creative=165953& creativeasin=b00c7kubr8&linkcode=xm2&tag=c99-gd-20 If the heat press is dedicated to curing the ink, the Teflon covers should be cleaned daily if parchment paper is used. If the Teflon covering is used directly on the print surface, the Teflon surface should be wiped clean after several uses to avoid any ink residue from previous cures from marking the upcoming garments to be cured. If the heat press is used for other applications, be sure no residue from that application remains or it may contaminate anything that could make contact with the printed surface. The Curing Pressure is too High The recommended Ink curing pressure is pounds of pressure. If too much pressure is applied to the printed garment the excessive pressure will cause the covering to adhere to the garment, although only slightly, it is enough to pull the cotton fibers through the white ink base. If the covering is dirty, higher pressure will amplify the effect of high pressure of the heat press. High White Ink Settings Certain designs may require a high values for the highlight and mask settings of the print driver. Usually artwork with large bold white lettering. If there is no CMYK ink to be printed in the design there may be some puddling of the white ink which may smear if a covering is placed upon it before the ink stabilizes. This would be very rare or non-existent for the GT-361 printer since that model would need two platen passes to complete the design. Since the GT-381 will complete the print in one platen pass the ink has less time to stabilize. When CMYK ink is printed as well, the increased amount of white ink may not be completely stable and white ink may appear through the CMYK ink. It will be most noticeable in the Cyan color. There are two remedies for this effect with large white ink volume when printed with CMYK ink. Program the design in machine mode of GT-361. This will use only the W1 & W2 print heads (take note of the ink levels of the white ink cartridges since W1 & W2 will be the only cartridges used in this situation). The platen will have to complete two passes to complete the design. The first pass will print approximately half of the white ink and the second pass will print the remaining white ink and the CMYK ink. The other option is to keep the machine mode as GT-381 but to check the White Pause box in the
11 advanced page of the print driver menu. This will make the printer perform two platen passes as well however the first pass will print all of the white ink and the second pass will print all of the CMYK ink. The time required for the first platen pass should provide enough time for the white ink to stabilize to accept the CMYK. The use of any of these two remedies will almost double the print time due to the second platen pass. Wrong type of covering (parchment paper type) placed on the uncured garment The recommended type of parchment paper is silicone based for heavy grease use. Too thin of a coating on the parchment paper will not provide a sufficient non-stick protection. Parchment paper with insufficient protection will pull the fibers up from the garment as you attempt to peel the parchment paper from the garment. Ink may pull off of the garment as well leaving bare spots. The following link is for a supplier of parchment paper that has performed well. Silicone/dp/B00C7KUBR8?SubscriptionId=AKIAIQWHH4HRPK7LRQTQ&camp=2025&creative=165953& creativeasin=b00c7kubr8&linkcode=xm2&tag=c99-gd-20 Inconsistent heat press base soft spongy foam base surface Many heat presses have a layer of thick foam rubber on the bottom plate. When the press is closed there may be some inconsistencies from one section to another as to the compression of the garment. These inconsistencies can cause some quality issues. A fitted Teflon lower plate cover will help provide a more consistent pressure. The change of the firmness of the lower surface will be very noticeable by hand. The manufacturer should be able to supply you with the correct size top and bottom fitted Teflon coverings. Improper Pretreatment application (amount/grams) If the pretreatment application is excessive it will not cure properly. The surface of the pretreatment will still make the white ink vibrant however when the ink is cured it is very possible that the pretreatment and ink will crack. Please see the guide for pretreatment and curing garment profile for recommended pretreatment values. You may have to calibrate the settings of your pretreatment machine to verify that the proper amounts are sprayed. Double printing applied (white +color) It is never recommended to reprint the same design on top of previous print. It may work for the most part when a CMYK only print is reprinted but realize some of the lighter shades may become darker than desired. A white only print can be done as well but the may be a challenge in curing it properly. You may have to let the heat press element hover over the surface for a minute before pressing the garment to cure double the amount of ink. If a conveyor dryer is used the garment should be allowed to cool after the first pass through the dryer and then passed through a second time.
12 The reprint that should never be done is Color+White prints. Although it may appear to work, the white ink will likely come through when the parchment paper is removed because the ink will not be cured sufficiently due to double the amount of ink. Now even if hovering the heat press over the print is done to cure the ink the shirt will be lost as soon as it is washed. White ink can only bond to pretreat. As soon as the second print starts the white is now being applied to a layer of CMYK ink. Although it may seem to cure the wash will remove most of the second layer. It is better to address the issue that made you want to print over the original print. Your dealer(s)-distributor(s) are your first line of support, please contact them for prompt assistance. If you do not have a dealer(s)-distributor(s) refer to our website For additional information contact Technical Support at or tsupport@brother.com. Any information within this document is subject to change.
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