Discharge printing is a go-to method for screen printers who want vibrant prints with a soft feel on dark garments. Traditionally, this process requires water-based discharge inks, which can present challenges like screen drying, ink management, and different curing requirements.
But did you know you can achieve discharge effects while using plastisol inks? That’s where plastisol discharge printing comes in. By adding a discharge additive to your plastisol ink, you can remove the dye from the garment while keeping the benefits of plastisol printing.
In this video, we cover how plastisol discharge works, its benefits, and how you can incorporate it into your shop.
What is Plastisol Discharge?
Plastisol discharge is a hybrid printing technique that combines the soft-hand feel of discharge printing with the versatility of plastisol inks. Instead of using water-based discharge inks, you mix a discharge additive with your existing plastisol inks to achieve the same dye-removal effect.
This method is perfect for shops that want to:
✅ Test discharge printing without switching to water-based inks
✅ Use plastisol inks they already have instead of investing in discharge bases
✅ Create a discharge underbase for softer, more vibrant prints
RELATED: DISCHARGE PRINTING DONE RIGHT
How Does Plastisol Discharge Work?
Traditional discharge printing removes the dye from the fabric, essentially bleaching it back to a natural cotton color. Pigments can then be added to recolor the design. Plastisol discharge follows the same process, but instead of requiring water-based inks, you use plastisol with a discharge additive.
🔹 Mix It Up – Combine a plastisol discharge additive with your plastisol ink at a 50/50 ratio by weight.
🔹 Activate It – Add 5% discharge activator (based on the additive portion, not total ink weight).
🔹 Print & Cure – The ink prints like plastisol but discharges like a water-based ink.
Because the discharge additive has no binders or resins, it evaporates during curing, leaving behind only the plastisol pigment. The result? A breathable, soft print with reduced ink buildup.
Why Use Plastisol Discharge?
Easy Transition to Discharge Printing
If you’re unsure about committing to full water-based discharge, plastisol discharge lets you experiment without a complete ink system overhaul.
Works with Your Existing Plastisol Inks
No need to invest in separate discharge bases or pigments—just mix a discharge additive with your favorite high-opacity plastisol inks.
Soft-Hand Underbase Option
Use plastisol discharge as an underbase instead of thick white plastisol. This helps top colors appear more vibrant and keeps prints lightweight.
No Screen Drying Issues
Since plastisol inks don’t dry in the screen, you avoid the fast drying time and screen clogging that comes with traditional water-based discharge inks.
Things to Keep in Mind
⚠️ Ink Opacity Matters
Since plastisol discharge reduces ink opacity, it’s best to use highly opaque plastisol inks like Wilflex Rio or Union Max Opaque for better coverage.
⚠️ Red Pigments Can React Differently
Some red pigments may fade or turn brown due to the discharge activation process. If this happens, try adjusting the plastisol-to-discharge additive ratio (e.g., 70% plastisol, 30% additive instead of 50/50).
⚠️ Ink Maintenance & Misting
Plastisol discharge is an evaporative product, meaning it can dry out faster than standard plastisol. Occasionally misting the ink can help maintain consistency during long print runs.
Is Plastisol Discharge Right for Your Shop?
Plastisol discharge is a great solution for screen printers who want to experiment with discharge printing while keeping the familiarity of plastisol inks.
If you love the soft-hand feel of discharge but prefer the workability of plastisol, this method offers the best of both worlds.
🔗 Shop Plastisol Discharge Inks & Additives: https://www.screenprinting.com/collections/discharge-inks