Printing with discharge ink is a fantastic way to create a vibrant print that’s unbelievably soft. But discharge printing isn’t for everyone. Let’s break down what discharge is, how it works, what you’ll need to get started, and how to get the best results.
WHAT IS DISCHARGE AND HOW DOES IT WORK?
Discharge ink is a water-based ink with a twist. Unlike traditional water-based inks, discharge includes an activator that removes dye from cotton garments. This process essentially “bleaches” the shirt's dye, restoring it to its natural fiber color, usually a light tan, and allows pigment to replace it. The result is a print that feels incredibly soft because the ink becomes part of the fabric rather than sitting on top of it.
When the ink reaches about 230°F under a forced air conveyor dryer, the chemical reaction begins to activate. Once the ink reaches 260°F, dye removal is mostly complete. But here’s the catch...it must still be fully cured like any water-based ink. That means heating the entire ink layer to the ink's cure temp and ensuring it stays at temperature long enough for the activator to do its job and for the pigment to set properly and moisture to evaporate.
The activator typically contains Zinc Formaldehyde Sulfoxylate (ZFS), which breaks down the dye molecules. As the temperature rises, formaldehyde releases and reacts with the fabric dyes. After that, sulfur binds with the formaldehyde to create a neutral molecule. However, not all of it neutralizes, which is why strong ventilation is critical in any shop using discharge.
Some printers may experience allergic reactions to the sulfur content. If you or your team have sensitivities, wear gloves and take precautions when mixing, using, or reclaiming discharge inks.
RELATED: Multicolor Discharge Printing With a Twist | Deep Dive with Colin
WHAT INKS YOU NEED TO PRINT DISCHARGE
There are two main methods for discharge printing: water-based systems and plastisol-based discharge. Both have their advantages, but each requires specific materials and equipment.
Option 1: Water-Based Discharge (Aquarius System)
This is the most common approach. Using a discharge base like Zodiac Aquarius Bright Discharge mixed with pigment and activated with Ryonet Discharge Agent gives fashion-forward shops a lightweight, breathable print.
Pair it with Baselayr Complete or Chromaline Hydro-X Red emulsions for stencil durability.
- Use discharge-compatible pigments or the Green Galaxy Fusion Mixing System
- Ensure you’re using screens with tight mesh tension for consistent prints
- Mix ink only as needed—once activated, the ink has a limited pot life
RELATED: Which Emulsion is Right for Me?
2: Plastisol Discharge
Want a softer print but love the handling and opacity of plastisol? You’re in luck. Plastisol discharge is a hybrid process where you mix RyoCharge with plastisol ink to activate dye removal while keeping your colors intact. Mix 30–50% RyoCharge with your existing ink and test different fabrics for reaction strength.
LEARN: How to Get Softer Prints with Plastisol Discharge Inks
WHY CURING AND AIRFLOW MATTER
Discharge ink needs more than just heat. To fully activate the chemistry and achieve a stable, washable print, your dryer must deliver:
- Consistent temperature: full cure temp across the print surface
- Sufficient dwell time: Hold temperature for 90–120 seconds
- Active airflow: This helps vent steam and fumes, critical for both safety and curing
Most infrared conveyor dryers rely only on radiant heat. That’s fine for plastisol, but not for discharge. Without air circulation, steam stays trapped in the ink film, causing ghosting, odor, and poor wash durability.
We highly recommend a RileyCure Forced Air Flash Dryer for on press or a forced air conveyor dryer for consistent, professional results.
TYPE OF FABRIC MATTERS
Discharge only works where the chemistry can reach and alter the dye. That means 100% cotton or high-cotton blends with reactive dyes are best. Shirts with polyester or rayon will not discharge evenly, if at all. Heathered or tri-blend fabrics might show partial discharge for a textured effect, but expect color shifts and inconsistencies.
Always swab test new garments before production. Some garments may be over-dyed—a second dye bath applied to adjust or salvage the original color. These usually resist discharge or produce uneven results. Ask your supplier if the garments are discharge-rated and test with activated clear base or color to check compatibility.
Major brands use an A-B-C scale to indicate discharge friendliness:
- A: Excellent reaction and color lift
- B: Generally good but test first
- C: Inconsistent or poor results—use for experimentation only
RELATED: How to Test for Dye Migration Before You Print
WHEN (AND WHEN NOT) TO USE DISCHARGE
Discharge is ideal for:
- Soft-hand, vintage-look prints
- Retail and fashion apparel
- Printing on dark 100% cotton garments without a heavy white underbase
But skip discharge if:
- You’re printing on kids' apparel: Discharge is not CPSIA-certified.
Learn about CPSIA - You have no ventilation or dryer venting
- You’re working with poly, rayon, or blends
- You can’t test every run
- You need ultra-fast production
READY TO START PRINTING DISCHARGE?
Discharge is a powerful tool in your screen printing arsenal. With the right setup, ventilation, chemistry, and fabrics, you can achieve rich, vibrant, soft-hand prints that feel like part of the garment itself.