Ryonet Discharge Base
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After extensive market and beta testing Ryonet Discharge is out performing the competition and saving screen printers time and money. Find out for yourself why customers are saying our new Ryonet Discharge lasts longer in production, penetrates the garment better, prints through higher mesh, feels better after production and creates an overall more consistent print versus previous discharge inks used in the past. Our unique formula for Ryonet Discharge & Ryonet White Discharge looks and feels more like an ink than a water based discharge. Once you open the container your can immediately tell Ryonet Discharge is creamier, has more body, and looks brighter than any other discharge you may have used in the past. Find out for yourself what customers are raving about with Ryonet's new Ryonet Discharge and Ryonet White Discharge.
Ryonet Discharge needs to be activated by Discharge Agent which is a powder that is mixed into the discharge ink 4-6%. You should only activate as much discharge as you will need to print at a given time as it does have a life span of about 6-8 hours once mixed. Discharge Agent is a powder and can be ordered by the pound. Discharge ink can be used with most 100% cotton shirts (does not work on poly or poly blend fabrics).
A water proof direct emulsion should be used for optimal performance. WBP Emulsion.
60-80 Durometer square edge. (Ryonet recommends 60 or 70 Durometer)
- Pigments: Mix 10% or less pigment with 100% discharge binder making sure to mix pigment into binder before mixing in the discharge agent.
- Discharge Agent: Should be mixed 4-6% into 100% discharge binder (by weight).
Printing:Once discharge agent is mixed into the discharge (with or without pigment) print directly onto fabric.
An under base can also be accomplished by printing discharge ink, which discharges the dye from the fabric, flashing, and over printing wet on wet w/ RC Ink. For the ultimate brilliance and soft hand results try our premixed White Discharge which has white pigment mixed in into the discharge leaving a discharged white under base.
Water based inks cure differently from standard plastisol inks. While plastisol inks cure with infrared once reaching 320 degrees, water based inks cure best with air movement and heat. Air movement is preferred to drive water out of the ink and blow away steam so heat can cure water base pigment properly. Without hot air movement across the ink, water based inks will take much longer to cure. In good air flow, water based inks can cure in under 1 minute while it may take 2.5 to 3 minutes in a standard infrared dryer (paper can be allowed to air dry).
We strongly suggest wash testing and documenting cure times before beginning production
Card off excessive ink and dispose of in trash. Use Sprayway Water Base Screen Opener or Enviro Solve to break down ink then wipe residue from screens, screen frames, squeegees and any surfaces in contact with ink. Left over residue can also be washed in the sink with water after soaking.
It is highly recommended to wash and dry garments or fabrics before packaging and shipping.
Methods of using discharge
Discharge inks require an activator/catalyst to work; there are two different systems available. The predominant system relies on active ingredient Zinc-Formaldehyde-Sulfoxylate (ZFS). The newer, and less used system relies on Thiourea Dioxide as its active ingredient. There are different name determinations dependent on what the ink company calls it, in most cases formaldehyde is the active ingredient. In both systems, the ink has a limited discharge life once the activator is added. There are two methods of discharge printing, both systems can be used.
- The first and most traditional printing method is to discharge every color in the print; there is no need for an underbase screen. In this format you mix pigments into the discharge to give it color when discharging occurs. PC pigments can be ordered in a variety of different colors and are typically mixed at about 10% into the discharge base. This method saves a screen and does away with flashing between colors. The exception to this rule is when a black-ink screen is needed. There's no need to use discharge if the black will cover without it. When printing on black, any black that is on the design is reversed, that part of the design will use the shirt color itself.
- The second method is to use discharge strictly as an underbase. With this method, you can use either white discharge or natural discharge, which contains no pigment and reveals the natural color of the fabric. The following colors are printed with regular plastisol with or without flashing. Some prefer not to flash the discharge underbase. This saves the head used for the flash and any cool down heads. The end result is that printers can increase the amount of colors they can print on dark shirts by one or two.
The white discharge underbase works well for most design types, especially spot-color work. Even though the other colors are printed using plastisol, the overall print has a less heavy feel because the underbase is a water-based product. If a design contains halftones or other areas with very thin ink deposits, then a natural discharge would work much better. The pigment in the white discharge underbase might mix with the process inks and shift their color. This is usually a problem with spot colors.
Discharge underbasing makes true 4 color process printing on dark fabrics possible. For process printing do not use a white discharge underbase. When the white pigment mixes with the transparent process inks, they will turn pastel and muted. Work with a natural discharge underbase that will reveal the natural cotton background color using a highlight white to make the design pop. Again if the design contains any white color of its own, print a white highlight that is designed to print with the process inks using this application.
Safety in production
Water-based ZFS-activated discharge is the most used and the most versatile method of discharge printing. ZFS has an unpleasant odor and should be handled carefully in its crystal form then blended into the ink by a properly trained employee. Always blend the ZFS slowly until it is well mixed in the ink to prevent dust, ZFS is relatively safe once in solution. Formaldehyde is a skin irritant. Proper procedure dictates dryers should be properly vented, never use an unvented dryer for discharge curing. Shirts printed with ZFS discharge have measurable levels of formaldehyde. Garments that are allowed to sit for a time after printing in an unconfined state will disperse most of the formaldehyde within days. If at all possible, avoid folding and packing ZFS-discharged garments immediately after printing.