In many print shops, the darkroom becomes a bottleneck. Manual steps slow down production, waste labor, and create inconsistencies that show up on press. The right automation strategy changes that. This guide walks through a natural sequence of upgrades that bring efficiency and repeatability to your darkroom.
Step 1: Consistent Coating With Automatic Coaters
Consistent stencil thickness is essential for predictable exposures and repeatable ink deposit. Manual coating introduces variation. Automatic coaters like the Grunig G-Coat 406 and the SAATI Pro Coat 25x36 eliminate that variation while reducing fatigue.
Grunig G-Coat 406
The G-Coat series offers compact solutions for both standard and oversized frames. The 406s handles screens up to 27.5 x 39.4 inches, while the 406xl extends to 39.4 x 55 inches. Operators can apply up to 10 coats per side, simultaneously or individually. Its plug-and-coat design requires no professional installation.
SAATI Pro Coat 25x36
This unit coats two screens simultaneously, front and back, for common frame sizes like 20x24, 23x31, and 25x36. It can also handle a single screen up to 53 x 49 inches. A touchscreen interface, programmable settings, and smooth belt-driven operation make it reliable and user-friendly.
Step 2: Smarter Imaging With CTS
Film is fragile, inconsistent, and slow. Computer-to-screen technology removes those issues by imaging directly onto the screen. Registration tightens, setups speed up, and production output increases. Options include the Exile Spyder X CTS and the Exile Spyder II.
Exile Spyder X CTS images at 600 dpi with 70 LPI halftones, covers about 2.4 square feet per minute, and supports frames up to 30 x 43 inches with an adapter. The maximum image size is 24 x 29 inches, while its compact footprint keeps it easy to place in most darkrooms.
Exile Spyder II is another proven CTS option. It also images at 600 dpi but supports halftones up to 75 LPI for finer detail. Depending on the model, the Spyder II handles larger frame sizes, with image areas up to 25 x 30 inches. This makes it well suited for shops running oversized work or looking for maximum halftone capability.
RELATED: THE EASY WORKFLOW OF THE SPYDER CTS
Step 3: Reliable Exposure With Baselayr VT
The Baselayr VT exposure unit uses even LED light to produce accurate, repeatable results. When paired with CTS imaging, detail is preserved and setups become faster and more reliable. This combination reduces guesswork and maintains consistent exposure times across emulsions.
RELATED: Darkroom Optimization 101: How Many Screens Does Your Shop Really Need?
Step 4: Washout and Filtration With Sgreen
Sgreen washout booths are built from tough, corrosion-resistant materials that hold up to years of use in a wet environment. Their smooth surfaces make cleaning quick and easy, while the integrated backlit system helps you see fine details during reclaim. Designed with printers in mind, these booths keep water contained, minimize splashing, and give your darkroom a professional, organized workflow.
Pair your booth with an Sgreen filtration system to capture solids before they reach the drain. This protects your workspace and the environment while simplifying clean-up.
Step 5: Automated Reclaim With Bluewater
The Bluewater R-2536S reclaim system integrates the full reclaim process into one machine. It processes about 25 screens per hour, runs on 208–230 V three-phase power, and requires about 8 cfm at 100 psi. Built in the USA, it comes with a 24-month parts warranty.
Bringing It All Together
Automation works best when each step supports the next. Auto coaters ensure uniform stencils, CTS delivers precise images, Baselayr VT exposure units harden detail, Sgreen booths manage washout responsibly, and Bluewater systems reclaim screens efficiently. Together, these upgrades reduce waste, save labor, and increase consistency on press.
RELATED: Reclaim More Than Just Screens With Bluewater Labs Inline Reclaim Systems
Quick Specs
- Grunig G-Coat 406: up to 39.4 x 55 inch frames on 406xl, up to 10 coats per side.
- SAATI Pro Coat 25x36: coats two screens at once, touchscreen programmable, single screen up to 53 x 49 inches.
- Spyder X CTS: 600 dpi, 70 LPI, 2.4 sq ft/min, max image 24 x 29 inches.
- Spyder II CTS: 600 dpi, 75 LPI, image sizes up to 25 x 30 inches (DTS 30).
- Baselayr VT: LED vertical exposure for consistent, repeatable results.
- Sgreen Washout Booth + Filtration: clean, compliant, and environmentally safe.
- Bluewater R-2536S: about 25 screens per hour, three-phase power, 24-month parts warranty.
Next Steps
Every shop has unique needs. Begin with the upgrade that will relieve your biggest darkroom bottleneck, then build from there. Whether it is coating, imaging, exposure, washout, or reclaim, the right automation steps will keep your press team moving and your prints consistent.