Welcome to a new episode of Deep Dive with Colin—Long Beach Edition. In this episode, I sit down with John from Avient, a seasoned expert in the screen printing industry. John has worked with some of the biggest names in ink manufacturing, including Union, Rutland, Wilflex, and now Avient. If you’re looking to master discharge printing, this conversation will give you valuable insights into techniques, troubleshooting, and creative ways to make your prints stand out.
Let’s get into it.
WHAT IS DISCHARGE PRINTING?
Discharge printing is a technique that removes dye from fabric and replaces it with new pigment, rather than layering ink on top like traditional plastisol printing. Think of it as localized dyeing—you are controlling specific areas of the garment instead of coloring the entire fabric.
This method creates incredibly soft prints because the ink bonds with the fabric rather than sitting on top. There’s no heavy ink feel, just a smooth, breathable design.
A common misconception is that discharge printing is the same as bleaching. Bleach damages fabric fibers, while discharge ink is formulated to strip the dye without weakening the material.
WHY USE DISCHARGE PRINTING?
Discharge printing produces prints that are softer, more breathable, and more natural-looking compared to traditional plastisol prints. The colors are more vibrant, especially on dark garments, without the need for a thick underbase. Since the ink fuses with the fabric, the print won’t crack over time.
It also allows for unique effects like soft gradients, vintage fades, and tie-dye styles without excessive labor. While it requires extra steps, discharge printing gives screen printers a competitive edge by offering something different from the usual plastisol prints.
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WHAT GARMENTS WORK BEST?
Discharge printing works best on natural fibers, especially 100% cotton. Bamboo and hemp also discharge well.
Cotton-blend shirts will only discharge partially, depending on the polyester content. Some colors, such as greens, royal blues, and certain reds, do not discharge evenly due to the way they are dyed. Testing is always recommended before committing to a full run.
A quick way to test if a garment will discharge well is to apply a small amount of discharge ink on a fabric swatch and run it through the dryer. Many blank shirt suppliers provide discharge rating charts, so check with your manufacturer if you are unsure.
EQUIPMENT NEEDED FOR DISCHARGE PRINTING
Printing discharge ink on a manual press is possible, but having the right equipment will make a huge difference in the final result.
A gas conveyor dryer is ideal. Small electric dryers are usually not sufficient because discharge ink requires at least 90 seconds of dwell time to fully evaporate the water.
Mesh screens should range from 110 to 230 mesh count, depending on the level of detail in the design. The emulsion needs to be water-resistant, as discharge ink is water-based and can break down weak emulsions. Post-exposing screens can help improve durability.
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Before adding discharge ink to the screen, wiping the mesh with water will help prevent the ink from drying too quickly.
HOW TO PRINT WITH DISCHARGE INK
Discharge ink is a two-part system consisting of a base and an activator powder. Once mixed, it should sit for 10 to 15 minutes before printing. Keeping the lid tightly sealed helps minimize evaporation.
For best results, use a 60/90/60 durometer squeegee. Start with a 15-degree angle and light pressure. The first stroke should lay the ink down, and the second stroke should clear it.
Since discharge ink dries fast, keeping the screens hydrated is critical. Always flood the screen when pausing, and if the ink behind the squeegee starts to look chalky, mist it with water to keep it flowing.
Proper curing is essential. A conveyor dryer should be set to 320°F to 330°F with a dwell time of at least 90 seconds. A forced air dryer will help evaporate moisture more efficiently.
Once the shirts come out of the dryer, giving them a quick snap will help remove any remaining dye dust.
CREATIVE DISCHARGE EFFECTS
Discharge ink opens up a range of creative possibilities beyond traditional screen printing.
Spraying discharge ink through a stencil creates a grunge-style effect. Watering down discharge ink and painting it by hand allows for artistic, one-of-a-kind designs.
For a reverse tie-dye effect, twisting the fabric and spraying discharge ink creates a black tie-dye look without the need for rubber bands or dipping. Using expanded metal mesh, pantyhose, or textured materials as stencils can create unique textures in the print.
COMMON MISTAKES AND HOW TO AVOID THEM
Discharge ink dries quickly, so keeping the screen hydrated is essential. If ink starts drying in the screen, flooding it or misting it with water will keep it from clogging.
If a print looks vibrant out of the dryer but fades after washing, it likely wasn’t fully cured. Increasing dryer time or temperature will solve the issue.
Uneven discharge results usually come from inconsistent curing. Ensuring even heat distribution in the dryer will prevent patchy results.
If the mesh clogs quickly, using a coarser mesh count and mixing the ink thoroughly before printing will help maintain smooth ink flow.
IS DISCHARGE PRINTING WORTH IT?
Discharge printing takes time and experience to master, but it allows screen printers to offer premium, high-end prints that stand out. While special effects printing may not always be the most profitable service, it is a great way to gain attention in magazines, trade shows, and competitions.
Winning an award at an industry event, even if it’s third place or an honorable mention, gives you the right to call your shop an "award-winning screen print business" and market yourself as a leader in the industry.
Discharge printing isn’t just another technique—it’s a way to create high-quality, fashion-forward prints that set your shop apart. With the right tools, knowledge, and creativity, you can master this process and offer something truly unique to your customers.