Flat Screen vs Rotary Screen Printing

Flat Screen printing is done by using a flat screen that moves up and down, and the design is printed on the substrate through a squeegee. On the other hand, in Rotary screen printing, the screen is in a circular form that rotates at the same position. This article will discuss the differences between them: Flat Screen vs Rotary Screen Printing.

In the modern textile industries, such as apparel and home furnishing sectors, both these printing systems are widely used, where the volume of production and pattern precision are key determinants of process selection. Comparison of advantages and disadvantages and understanding their working mechanism helps in selecting the right printing method for each type of textile product.

What is Screen Printing

Screen Printing is the most common technique of printing that is used in the textile sector. In this, ink is passed through a woven mesh stencil, which is blanked and blocked according to the design structure. The ink paste is pressed to pass through the mesh, and printing is done from the blank area of the template.

Different types of fabrics can be printed through screen printing with mass production, which is why it is a very popular technique in printing.

Screen printing has evolved from hand processes to automatic systems equipped with electronic controls, servo drives, and highly precise registration units. This latest advancement ensured high accuracy in multicolor registrations and decreased manual dependency. The process is preferable for all printing methods such as pigment, reactive, and discharge printing, and its selection depends on the fabric composition.

Types of Screen Printing 

The main types of screen printing are:

• Flat Screen Printing
• Rotary Screen printing

Other specialized printing, such as digital hybrid screen printing and semi-rotary printing, has also emerged, which allows printing combinations for niche markets. For woven and knitted fabric printing, flat and rotary printing are industrial benchmarks.

Overview of Flat & Rotary Screen Printing 

The flat screen, also known as a Flatbed printing press, can be done manually and automatically, while a rotary screen printing machine is automatic and has a higher production speed as compared to a flatbed. A flat screen printing machine uses a squeeze, and rotary screen printing uses a roller to print the substrate.

The selection between these two depends on multiple parameters, such as design, size, required depth of color, production scale, and type of article, such as woven, knitted, or nonwoven. Flatbed printing system is typically used for short runs, sampling, and delicate design, while rotary printing in preferred for continues and large-scale production.

Flat Screen Printing

Today’s flatbed screen printing has become automatic, before it was done y manual method. It is done on a specific area of fabric, with a limited number of colors 4 – 8. For each color and design separate stencil has been made to print on the substrate. Ink paste is passed through the stencil by squeegees.

How Does Flat Screen Printing Work? 

Flatbed printing is manual, semi-automatic, and automatic. In automatic flatbed printing, firstly, fabric is glued on the surface of the conveyor belt. Then the screen is lowered on the fabric’s surfac,e and ink paste is passed through the screen by using a squeegee.

Each color has a separate stencil, in the same way the belt moves forward, and each color screen is lowered to the fabric to complete the design and pattern. Then the fabric goes to the drying chamber, which is attached at the end of the flatbed machine.

Airflow and temperature of the drying chamber are critical because uneven drying can cause the migration of dyes or pigments or spot marks. For a reactive and disperse system, subsequent steaming and washing are carried out to fix the fixable color and remove unfixed dye to improve the colorfastness property of the finished product. Sharp outlines are ensured by proper viscosity control of printing paste, which reduces screen choking risk.

Let’s see the advantages and disadvantages of flatbed screen printing.

Advantages of Flat Screen Printing 

• Cost Effective

Flatbed printing is cost-effective as compared to rotary printing.

• Versatile

This can be done on various types of fabrics and a wide range of designs can be printed through this printing technique because it supports to use of different mesh-size screens.

The flatbed machine can print CMYK designs more precisely as compared to rotary printing. It can easily pass the nickel test (no nickel in cloth) as compared to rotary printing.

• Durability

Flatbed printing results are more durable as compared to other printing techniques. Its result is sharper and longer-lasting than rotary print. It does not damage the screen while running.

A rubber squeegee is used in flat screen, while in rotary blades or a stainless steel roller of different diameters is used to print the cloth.

It produces repetition marks while rotary printing the overall body without joint marks.

• Number of Colors 

In a flatbed, you can print 8 – 12 colors, while in a rotary, there is the option of using up to 24 colors.

• Sharp Results 

If we see result-wise, flatbed gives a sharper result as compared to rotary print. Fine lines, pixel lines, and spray or dot patterns can be easily printed through flatbeds.

• Various screen sizes 

This printing technique allows to printing designs of various sizes. Each color has a separate screen so you can easily use various measurements of mesh size screens to get the desired results.

• Less pollution

In flatbed printing, color waste is less as compared to rotary printing.

• Easy & Simple 

It is quite an easy and simple technique of printing as compared to rotary printing. In this method, simply the screen moves up and down so there is less chance of pin holes. In rotary printing, there is fast cylindrical motion of screens which may cause pin holes in printing.

The screen engraving of flatbeds is quicker than rotary screens. It took 30 minutes or less to prepare a flatbed screen, while a rotary screen takes more than 30 minutes to prepare.

The flat screen printing provides complete control over dyes or pigments, ink deposit thickness,s which makes it ideal for printing puff, flock, metallic, and discharge effects. Its slower pace allows the technicians to detect errors on the initial stage and improve first-quality yield. Its modular design makes the changeover between print runs very easy, which is beneficial for custom fabric development or sampling labs.

Disadvantages of Flat Screen Printing 

• Material Handling 

Flatbed has a disadvantage in the case of material handling. It requires drying equipment and a rewinding unit to prepare the printed fabric.

• More Labor Cost

In the case of multi-color printing, its labor cost increases due to the making and operation of a new screen for each color.

• Combine Printing

This is the other major disadvantage that you cannot take overall print design on a flatbed. There will be a little gap. Combine printing can not an obtained from this technique, while it can be done on a rotary machine.

• Screen Choking 

The risk of screen choking in flatbed printing is more than in rotary printing. In a flatbed, ink paste is manually added on the edges of the screen. When the squeegee speed is enhanced for a longer width, the ink paste viscosity increases, which causes lumps and chokes on the screen.

The ink paste gets dry on the sides of the screen, which may also cause choking in case of the squeegee.

In continues fabric alignment and repeat accuracy for longer design, flatbed printing system faces many challenges. The downtime between color applications leads to productivity losses. Regular cleaning of screens is required to prevent pigment build-up and the improper tension of the mesh results in image distortion or misregistration.

• Rotary Screen Printing 

Rotary Screen Printing

It is the process of continuous printing in which rotating perforated cylinders are used which have the ink paste inside it. The paste is forced to pass through the cylinder’s holes to print on the substrate.

A dedicated pump is attached to feed the ink paste in the cylinders. A squeegee device is used to force the paste from the inside of the rotating cylinders to the outside of the fabric. Each screen has one color and overall 16 – 24 colors can be run on rotary.

The continuous process makes rotary printing very efficient for yardage production. The cylindrical screen shape allows for seamless design repeats ideal for fabrics requiring all-over prints like bed sheets, drapery and shirting materials.

How does Rotary Screen Printing Work?                                                            

Before printing any design, screens are prepared. Rotary screens are created on specially coated nickel material. This coating is burned with laser engraving to craft the design.

An aluminum ring is used at the ends of the rotary screen to hold it in the printer. These screens are very delicate that’s why they are held by aluminum rings otherwise they can be ruined.

Screens are adjusted and aligned with the printer as well as the ink paste. Each screen can give you two types of tones, blotch print and half-tone print. It depends upon the cutting level of holes from which how much ink can pass.

Each screen has two main parts, a magnet bar and a squeegee for pressing the paste from inside the cylindrical screens to control the printing depth using pressure.

Magnet bars are also known as color bars, which are made of metals and are attached to the magnet underneath the blanket.

The large and small magnet bars are used to control the printing and its sharpness. Large bars are used for mainly blotch printing and small bars are focused on outlines and sharp printing. It is just as in painting large and small brushes are used for better results.

Squeegee also moves along the magnet bars and applies constant pressure on the screen. It helps the ink paste to pass through the screen and to print on the substrate. To get consistent results, and avoid ink deposits and contamination, belts are cleaned constantly with a brush and water from the bottom.

The stock paste of inks or pigments is prepared in buckets which are attached with separate print heads using a suction pump. A sensor is installed in the pump which assesses whether the ink paste is further required or not.

After finishing the printing, magnet bars, squeegees, and screens are removed. These all things are washed and cleaned properly for further use.

The advanced machines equipped with magnetic roller drives, which are able to adjust pressure electronically for consistent ink laydown. The strength of the magnet and squeegee angle affect printing sharpness, so operator calibrate them according to the material GSM and paste viscosity. Some rotary systems are often connected with inline dryers and steaming units for high throughout, which maintains uniform colorfastness and curing efficiency.

Advantages of Rotary Screen Printing    

• High Printing Speed 

Rotary printing speed is 3 – 4 times more than flatbed. It can print 120 yards/min. Rotary is well known due to its high printing speed.

• Fast Change Over of Prints

This printing technique does not take too much cleaning and resetting process, which avoids repeated machine stoppage, save time, and helps to maintain consistent results and production.

• Cost-Effective In Longer Run 

It is more cost-effective only in case of a larger production.

Even at high speed, rotary printing ensures uniform ink distribution across the full surface of the fabric. Its automation level minimizes dependence on operator and color registration is digitally managed through servo control. With proper maintenance, a rotary unit can be operating continuously for 16-20 hours per shift and can achieve productivity exceeding 2500 meter/hours. Due to its compatibility with pigments, reactive and disperse systems, its versatile for both apparel and home textiles.

Disadvantages of Rotary Screen Printing 

• Costly in Shorter Run

Rotary print is not economically beneficial in case of shorter production, because its screens are carved on coated nickel material. Its engraving costs for a single screen go up to $300 – 1000. Each screen is used for a single color, and there can be up to 24 colors on the rotary.

It means you have to prepare 24 screens to complete the design. If you do only sampling, or take shorter production from rotary then it will be expensive due to the engraving cost of screens.

• Differences in Sampling & Production 

There could be differences in the results of sampling and production, because screen variables, supply of pigment or dye, and environment may vary.

• Color Limitations

There is a limitation of colors in rotary printing. Even high-class rotaries can print up to 16 colors per print area.  If we increase the number of colors the setup will get more complex and difficult to handle.

• Not Good for Fine Details 

The rotary printing screen has the drawback of achieving fine details and narrow outlines. This technique fails in printing photographs with sharp results.

• Fabric Alignment Issue 

At high speed, this machine disturbs fabric alignment which can cause skew.

• Unable to print Garments

This printing technique can only print fabrics from selvage to selvage. It is not suitable for knitted fabrics and garments.

Differences in Printing Mechanism

Screen Structure and Motion

Flat screens are stationary and move vertically, ideal for precise, smaller-scale designs while rotary screens are cylindrical and rotate for continuous patterns, suited for high-speed printing.

Ink Flow and Continuity

Rotary has continuous ink flow, minimizing stoppages and blockages, while flat requires frequent pauses for ink refilling.

Production Speed and Volume

If you need a higher production of printed fabric with consistent results in a specific period, then which printing should be done to meet the requirements?

There comes a huge demand for printed fabrics in specific weather and seasons, in Asian countries there is a great demand for lawn collection in summer seasons. So when you want to produce mass production with consistent results then you should go with rotary screen printing.

Rotary as reflected by its name, it would be a continuous process. That is why in textile industries when there is a demand for all-over designs with mass production, and then rotary printing is done to meet the requirements as compared to flatbed printing.

Flatbed 

Flat screen printing is slower, and better for smaller batches or custom, intricate designs.

Rotary

Rotary printing is significantly faster, handling three times the output of flat-screen printing, making it optimal for high-volume runs.

Print Quality and Complexity 

Color Capacity

Flat screens support 6-8 colors, suitable for detailed designs; rotary can handle 16-24 colors, producing complex patterns at scale.

Pattern Reproducibility

Rotary continuous rotation allows for uniform quality across large quantities, while flat screens excel in detailed work for limited runs.

Cost Considerations and Setup                                 

Initial Investment

Flat screen printing has a lower initial setup cost, making it economical for small to medium runs. Rotary requires a higher upfront investment but lower per-unit cost for large-scale production.

Screen Durability

Equipment’s lifespan plays an important role in overall machine maintenance and cost in the long run. If we see the lifespan of screens, then rotary screens are beneficial in the long run.

Although the engraving cost of a rotary screen is higher than the flatbed screen, its lifespan is much better than a flatbed screen. The long-lasting nature of the rotary screen saves time on the machine, which enhances production and it does not require the replacement of screens frequently.

Rotary screens are more durable, reducing maintenance and replacement costs, and contributing to their long-term efficiency in high-volume operations.

Ideal Applications 

Rotary Screen Printing

Preferred for large, continuous designs on wide fabrics, suitable for textiles requiring high durability, uniformity, and high production speed.

Flat Screen Printing

This technique is best for detailed, smaller-scale prints on narrower fabrics, where lower volumes and custom designs are prioritized.

Flat Screen vs Rotary Screen Printing

Let’s have a look at the key differences between these two printing methods.

Flat Screen Printing

1. The screen is flat and it moves vertically up and down.
2. To press ink paste squeegee is used, which can be manual or automatic.
3. Fabric with a small width of around 45” – 50” is printed.
4. In this technique, we can print 6 – 8 colors.
5. Its production capacity is lower. It can print 500 meters/hour.
6. Has a lower production rate.
7. Initial setup cost is low, and less expensive for startup.
8. This technique uses a minimum of two meters of fabric to print, one meter for refilling, and one meter for printing.
9. Brand names are KUIL (South Korea), INTOMA (Taiwan), Reggiani (Italy), Stork (Netherlands), YUJIN (Korea), Zimmer (Austria), and CST (Germany).

Rotary Screen Printing 

1. The screen is cylindrical and rotates at its position.
2. To press ink paste roller is used.
3. Fabric with a large width can be printed easily.
4. In this technique, we can print 16 – 24 colors.
5. Its production capacity is higher. It can print 2500 meters/hour. Rotary production is 3 – 5 times more than flatbed printing.
6. Has a faster production rate.
7. The initial setup cost is too high and expensive for a startup.
8. This technique uses a minimum of one-meter fabric to print.
9. Brand names are Reggiani (Italy), Stork (Netherlands), Zimmer (Austria), BUSER (Switzerland), MHMS (Austria), Harish (India), and Ji- long (China).

Conclusion

Flatbed screen printing is done by a stationary screen which moves vertically up and down and has lower production but gives good results in narrow work, like outlines, and single-pixel narrow lines. Its initial cost is low and good for a shorter run.

Rotary screen printing is done by rotating cylindrical screens, from which inks are pressed through magnet bars and squeegee. It has higher production but is not suitable for narrow work, or outlines. You cannot take good results photographs by this technique. 

In short, both techniques have their unique industrial significance and the decision between them is totally depends in required precision, cost targets, production batch size and substrate characteristics. The textile sector is moving towards sustainability, both systems are being upgraded with water-saving washing units and digital monitoring and low-waste paste circulation systems to enhance the efficiency of the machine and environmental compliance.

 FAQs

What is screen printing?

A woven mesh stencil is used for printing, which is blanked and blocked according to the design structure. The ink paste is pressed to pass through the mesh, and printing is done from the blank area of the template.

How many types of screen printing that are mostly used?

There are main two types of screen printing.

• Flat Screen Printing
• Rotary Screen printing

What is meant by flat-bed screen printing?

It is the name of the printing technique in which a stationary screen is used to print on the substrate. A manual or automatic squeegee is used to pass the ink paste from the screen.

In which case we should choose flat-bed screen printing?

This printing technique is best for detailed, smaller-scale prints on narrower fabrics, where lower volumes and custom designs are prioritized.

What is the deification of rotary screen printing?

It is the process of continuous printing in which rotating perforated cylinders are used which have the ink paste inside it. The paste is forced to pass through the cylinder’s holes to print on the substrate.

Which material is used for rotary screen engraving?

Rotary screens are created on specially coated nickel material. This coating is burned with laser engraving to craft the design.

Why aluminum ring is used at the ends of the rotary screen?

An aluminum ring is used at the ends of the rotary screen to hold it in the printer. These screens are very delicate that’s why they are held by aluminum rings otherwise they can be ruined.

How ink paste is pressed out of the rotary screen to the substrate?

The rotary screen has two main parts, a magnet bar and a squeegee for pressing the paste from inside the cylindrical screens to control the printing depth using pressure.

What is the function of magnet bars inside the rotary screen?

The large and small magnet bars are used to control the printing and its sharpness. Large bars are used for mainly blotch printing and small bars are focused on outlines and sharp printing. It is just as like in painting large and small brushes are used for better results.

In which case we should choose rotary screen printing?

It is preferred for large, continuous designs on wide fabrics, suitable for textiles requiring high durability, uniformity, and high production speed.

Why rotary screen engraving cost is higher than the flat-bed screen?

Rotary print is not economically beneficial in case of shorter production, because its screens are carved on coated nickel material. Its engraving costs for a single screen go up to $300 – 1000.

What is the difference between flat-bed screen printing and rotary screen printing?

Flatbed screen printing is done by a stationary screen which moves vertically up and down and has lower production but gives good results in narrow work, like outlines, and single-pixel narrow lines. Its initial cost is low and good for a shorter run.

Rotary screen printing is done by rotating cylindrical screens, from which inks are pressed through magnet bars and squeegee. It has higher production but is not suitable for narrow work, or outlines. You cannot take good results photographs with this technique.

Rotary is suitable for higher production, large designs, and big motifs. Its initial cost is high, but cost-effective in the long run.

What is the limitation of colors in flatbed & rotary screen printing?

In flatbed screen printing, you can use 6 – 8 colors, while the rotary machine is designed for the use of 16 – 24 colors. Normally technicians run 16 colors on rotary because the use of 24 colors makes a complex setup that is difficult to handle.

Which screen’s lifespan is better rotary or flat?

The lifespan of a rotary screen is better than flatbed. Its long-lasting nature makes the machine cost-effective for longer run. It does not need to be replaced frequently.

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