Here's a lowdown of the different prints we do:
Direct Screen Printing
This is the most popular method used for simple designs and often the most cost-effective. It is ideal for printing mugs in bulk as it transfers the image directly onto the body of the mug, quickly.
In the direct screen printing method, an image is printed, as in the title, directly onto the rotating body of the mug. This process begins when a design is received from the client. Vector graphics are needed as part of the order process, to ensure designs have smooth edges and do not display pixilation. The designs are broken down into separate line colours, which then become different screens for the process. The separate colours delivered by each screen in the direct process give bright and strong colour images – particularly on the shiny glaze surfaces of most earthenware and bone china mugs.
The screen, once placed in the machine and perfectly aligned, renders one colour per pass. The ware is left to dry for around 24 hours to harden before any subsequent colours are printed. The colours may lie next to each other, but other than black, no colours may overlay as a rule. This is an important element to know, as once placed in the kiln for final firing, the glazes temporarily become molten and may merge, which may create an unacceptable colour blend.
Each colour must remain in its own place, and independent from any adjacent colour. After firing, each ware is checked for quality, boxed and placed ready for carrier or client collection.
Transfer or Litho Printing
This process is used when designs have a little more detail and require a human touch. The design is printed onto paper, screened and then carefully transferred by hand onto the individual mug. This is ideal if the mug is a complex shape or if it needs to wrap around the mug. It also boasts a more extensive colour range than direct screen printing.
For surfaces, such as the delicate curve of a coffee pot or the lip of some bone china mugs, which cannot be printed in conventional forms, transfer printing is used. This process ensures a precise, well-placed image with carefully registered print, which can be affixed to almost any surface.
The colour separations are placed on a screen and printed onto a special wax coated paper. The colour lies on the surface of the wax, and will not be rolled or pressed in. On completion of the print, and after drying time, there is a final application of a clear coating, which envelopes the whole of the print. This is known as a cover coat, essentially a gelatinous layer, which holds the print together.
When soaked in warm water, the cover coat and print slide away from the wax surface, and can then be slid into position onto any surface. This process is suitable for the back or front badge of a beaker, a complete wrap design, the well and rims of a plate – even inside the rim of a mug.
All full-colour work and intensely registered prints and designs must be decorated using this method. When the ware is placed in the kiln for final firing, the cover coat evaporates at around 400 degrees Celsius leaving the enamel decoration on the surface of the ware. As the kiln temperature rises to 800 C, the enamels are fused into the surface of the ware glaze to form the finished print
Full-Colour Printing
Full-colour printing uses four colours which are recognised by most software so you can design in the office and send straight to us. We recommend printing off your design first as depending on the monitor the colours may vary. The colours are known as CMYK, a mixture of Cayenne, Magenta, Orange and Black.
Digital Printing
This method is only used on white mugs. Costs are kept to a minimum as we only charge for the design, not the actual work involved. Similar to a laser printer, the design is printed directly onto paper, overcoated and then applied by hand to the mug. Popular with photographs it makes pastel colours stand out.
The digital process uses advanced laser and ionisation techniques, which give the ability to have a series of mugs personalised or a short run of full-colour mugs.
Unlike other process methods for screen printing where line colours are used, in the digital process, the image in its full-colour form is recreated as a specific file. The image can then be output into a digital tone print on similar paper, as used in transfer printing.
The colours are expertly adjusted to lift and enhance the colours available in the process – an important part of the print management. The magenta colour used in the digital enamel range is not as strong or vibrant as the screen print magenta. Consequently, some rich high red colours are a little weaker, though pastel colours are outstanding.
The final digital print is cover coated, as with a transfer print, then water slid into position to decorate the mug. The print needs a top surface to hold the pattern in place, so a small, weak transparent keyline may be evident in the final print. To be realistic, and for the colours to gain the best effect, the process is best suited to white glaze only.
3D Printing
3D printing isn't a printing method per se. It involves adding clay to the mug to give it an embossed, 3-dimensional look. It certainly adds quality to the finished product and can make a logo, brand or design stand out. Mugs like these can often become collector's items.
This process involves shaping and moulding a piece of clay onto the outside of the ware before glazing. The raised surface can be coloured with transfer printing, as with the transfer printing process. The final product creates a novel and interesting visual aspect for your brand – ensuring you stand out from the competition in more than one way!
Print runs have a minimum of 1500 pieces, with artwork required as a vector or line image, with a single colour separation.