Reclaiming screens is one of the most fundamental skills in any print shop. If you do not remove your old stencils & emulsion correctly, you are setting yourself up for failure on the next job. Using the right emulsion remover is about more than just washing away chemicals; it is about protecting your mesh and ensuring every print comes out crisp.
In this guide, we will look at how to use emulsion remover to get your screens back to a pristine state. We will cover the tools you need, the chemistry involved, and why your cleanup process actually begins before you even enter the darkroom.
Why Reclaiming Is A Critical Step for Print Quality
When you look at a screen, you see a woven surface of threads. These threads create "knuckles" where they overlap. During a print run, ink and pigments get driven into the tiny crevices of these knuckles.
Think of the mesh knuckles like rocks in a river. As the water level drops, sediment settles around the rocks. In screen printing, that sediment is the pigment from your ink. If you do not use the correct emulsion remover and cleaning process, that pigment becomes locked in. This leads to image stains, ghosting, and a frustrated printer.
Start with a Clean Slate: Removing the Ink
Before you reach for your emulsion remover, you must clear the ink. However, the type of cleaner you use matters. Many printers reach for a fast-evaporating press wash. While great for quick color changes, these can actually dry out the pigment inside the mesh knuckles. This makes the pigment much harder to remove later.
Instead, use an ink degrader or multi-purpose wash that has a high surfactant count. Products like Sgreen Supreme Press Wash or Easiway Multi-Purpose Wash stay "moist" longer. They keep the area lubricated, which helps pull those stubborn pigments out of the mesh before the emulsion remover is applied.
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Choosing the Right Emulsion Remover
Not every shop has the same needs. Your choice of emulsion remover depends on your volume, your equipment, and your workflow.
| Type | Best For | Recommended Products |
|---|---|---|
| Ready-to-Use | Provides a convenient, no-mix application for fast screen turnarounds and shops looking for consistent performance without mixing chemistry. |
Sgreen Stripper |
| Concentrates | Offers a balance of versatility and value, allowing shops to adjust the strength to their specific needs and maximize their reclaiming budget. |
Easiway Concentrated Saati ER2 Emulsion Remover Saati ER6 Emulsion Remover |
| Unlock | For use when your emulsion has been on your screen for extended periods and has "locked in" to your screen. |
Franmar UN-Lok Locked Emulsion Remover |
| Gels/Pastes | Ideal for reclaiming large format screens or for use on vertical surfaces where the chemistry needs to cling to the mesh to fully penetrate. | Saati Gelative ER6 |
| Dip Tank | Built for production environments looking to streamline labor and water usage by softening multiple screens simultaneously. |
Easiway Dip Tank Solution Ryonet Dunk Tank Kit |
Ready-to-Use vs. Concentrates
Ready-to-use (RTU) formulas are convenient because they require no mixing. You just spray and go. Concentrates, however, allow you to mix the chemical with water at ratios like 1:10 or 1:20. This is a much more cost-effective way to buy emulsion remover if you are processing dozens of screens every week.
The Power of the Dip Tank
A dip tank can greatly speed up the reclaim process and save on chemistry. By submerging your screens in a solution of water and a chemical like Dip Tank Solution, the emulsion remover has time to penetrate the emulsion on both sides of the screen simultaneously. This softens the stencil so it practically falls off when you hit it with water in your washout booth.
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Step-by-Step Reclaiming Process
Once your ink is gone and your tape is pulled, it is time to use your emulsion remover.
- Wet the Screen: Apply water to both sides.
- Apply Remover: Spray your emulsion remover liberally.
- Agitate: Use a dedicated Sgreen Scrub Pad to work the chemical into the mesh in circular motions. Focus your efforts on the squeegee side of the screen, as that is where the most pigment and emulsion reside.
- Rinse: Use a pressure washer to blast the stencil out. A standard garden hose often lacks the PSI needed to clear the knuckles effectively.
The Golden Rule: Never let emulsion remover dry on your screen. If it dries, it can "lock" the emulsion into the mesh permanently. This often results in having to replace the mesh entirely.
Dealing with Stubborn Stains and Haze
Even when a screen looks "clean" to the naked eye, microscopic amounts of ink pigment or dried emulsion can remain trapped in the knuckles (the intersections) of the mesh fibers. This creates what printers call a "ghost image." Use a haze remover which breaks down those stubborn trapped pigments & emulsion to finish the job.
Clean Shop, Clean Water
Shops have a responsibility to look after their plumbing and the environment. As you wash away emulsion remover and old stencils, a lot of solid waste goes down the drain.
To keep your pipes clear and your shop eco-friendly, we recommend the Sgreen Filtration System. This system catches the solids and emulsions before they enter your septic or city sewer lines. It is a smart business move that prevents expensive plumbing bills and keeps your shop compliant with local regulations.
Keep Your Momentum
Reclaiming screens might not be the most exciting part of screen printing, but a solid routine with the right emulsion remover makes it effortless. By choosing the right chemistry for your volume and taking care of your mesh, you ensure that every job you put on press is set up for success.