Ever feel like your screens are always holding up production? You’re not alone. Many print shops underestimate just how many screens they need and how to manage them effectively. If you’re looking to get on press faster and cut down bottlenecks in your shop, it starts in the darkroom.
How Many Screens Do You Really Need?
Here’s a simple rule: You need about four to five times the number of screens you use per day. If you're printing with 20 screens daily, plan for 80–100 in rotation. This allows you to keep up with cleaning, coating, drying, and reclaim without slowing things down.
Why so many?
- Production screens: Jobs queued for the day.
- Clean screens: Washed, degreased, and ready to dry.
- Dried: Stored and ready to coat.
- Coated: Ready for burning a new image.
- Remesh pile: For screens that need repair or replacement.
Streamline With a Screen Cart System
If you’re not using a cart system, you’re probably wasting time and backtracking in your workflow. Here’s how a basic four-cart system can boost your efficiency:
- Speed Cart: Coated, imaged screens staged for press.
- Take Cart: Dirty screens coming off press.
- Clean Cart: Reclaimed and degreased screens ready to coat.
- Drying Cabinet: Screens drying post-coat before imaging.
Track Your Screen Usage
Want to know how many screens you really go through? Start tracking them. Use a whiteboard or spreadsheet in your darkroom to log mesh counts and daily usage. Then average that out monthly. Whether you're burning 10, 20, or 40+ screens a day, knowing your numbers helps you prep ahead and avoid costly slowdowns.
Screen Storage That Supports Your System
Don’t overlook where your screens live between stages. When it comes to drying freshly coated screens or simply keeping your flow organized, the Baselayr Screen Rack delivers. With space for 20 screens, it supports your cart system and gives your darkroom a clean, efficient rhythm.
Need more screens in rotation? Check out the full screen collection to stay stocked up and press-ready.
RELATED: WHY YOUR SHOP NEEDS AN LED EXPOSURE
Reclaim Smarter, Not Harder
Efficient screen reclaim is just as important as coating. If your reclaim station is messy, inconsistent, or constantly backed up, it’s going to hurt production. A proper washout booth keeps chemicals contained, improves your reclaim quality, and creates a professional-grade work zone.
Looking to scale? The Bluewater Labs Inline Reclaim Series is a high-efficiency solution built for serious throughput. It saves water, reduces labor, and streamlines your reclaim process from start to finish.
Keep Your Screens Flowing, Keep Production Going
When your darkroom runs smooth, everything else gets easier. Start with the right number of screens, set up a smart cart system, and stay on top of your screen usage. Your press (and your team) will thank you.
Need better tools for your darkroom? Explore Baselayr darkroom solutions to build a workflow that works as hard as you do.
Your success starts in the screen room. Let’s make it unstoppable.