The Union Ink ™ Plasticharge ™ additive DSPCH-9070 is a
unique water-based clear additive that is combined with a plastisol colored ink
and DSPP-9ZFS Discharge Agent to form a hybrid (water-base/plastisol) ink that
will discharge the original color from the underlying fabric while
simultaneously printing the desired new color in a single operation.
Selecting the substrate - Not all garments are designed to
discharge. They must be “reactive dyed” and natural fiber (100% cotton). At the
present time, most name brand 100% cotton shirts will discharge. Kelly Green
and Royal Blue substrates have historically been difficult to discharge;
however, recent testing indicates more positive discharge reaction.
Selecting a plastisol color - Technically, any plastisol can
be used to provide the color. However,
it is important to remember that the intensity of the color will be diluted by
the 50% Plasticharge additive component. Therefore, by using a high opacity
color, the end result will be a more accurate replication of the original
plastisol color. Union Ink recommends either Maxopake ™ or Mixopake ™ for the
plastisol component. Test results with these inks have, in most instances, resulted
in precise color matches.
Blending - Plasticharge additive is a hybrid product that
combines an aqueous discharge base component with color, provided by plastisol inks.
The two components should be blended at the recommended ratio of 50:50 by
weight. This ratio will approach maximum color accuracy and coverage. However,
printers can choose to alter this ratio to achieve to the desired finish, with
a higher ratio resulting in a softer finish.
This step can be completed in advance of production as pot life begins
to diminish 6–8 hours after the addition of the activator powder. The amount of discharge agent powder should be
determined by the weight of the amount of Plasticharge additive, rather than
the combined weight of the additive and the ink.
Activating the Plasticharge additive - To activate the
Plasticharge, add 5–6% discharge agent immediately prior to adding ink onto the
screen. Some garments will discharge
fully when as little as 4% of this activator is introduced; so, use the lowest
possible percentage to achieve the desired effect. Pot life of the ink at this point is
approximately eight hours. However, to achieve optimal performance, apply in
1–2-hour increments and only activate the ink needed for the time interval allotted.
For longer runs, the repeated addition of fresh Plasticharge additive to the
screen will help to keep the process working at peak efficiency.
Curing - Discharge is a steaming/extraction process. It is
very important the print is not cured using extreme temperatures Remember: longer
dwell time is more important than higher heat. See “Testing the Curing
Testing the curing process - When the project begins, first
run two prints down the dryer, then immediately run one of the prints through
the dryer again. Then, compare the two prints; if the prints look the same, the
dryer is ready for production. If the twice-cured print looks better, slow the
dryer and repeat the test until they match.
Remember, in the curing process, there is a plastisol component that
still must cure between 300°F–320°F (150°C–160°C). Therefore, in addition to
steaming the water out to enable the discharge function, it is also necessary
for the ink film to reach cure temperature. As the water evaporates, the
plastisol ink will not reach cure temperature until the discharge process is
complete. Thus, testing for complete cure is highly recommended.Requires ZFS Discharge Agent
View Union Product Documentation Here