Understanding Screen Printing for Packaging

1. What Is Screen Printing & Its Key Types

Screen printing involves forcing ink through a fine mesh screen onto a substrate. The mesh stencil blocks ink in non-image areas, allowing detailed, bold designs on surfaces including plastic, glass, metal, tins, jars, and flexible pouches.

Common variations include:

• Spot Color Printing: Single solid ink color applied via mesh stencil—ideal for logos and text .

• Halftone Printing: Uses dots to simulate gradients and complex shading, enabling multi-tone imagery with a single ink color .

• Duotone Printing: Combines two halftone layers (e.g. black and warm brown) to create artistic, sepia-like prints.

• Simulated Process Printing: Blends multiple halftone inks to mimic photographic quality or full-color print.

• Cylindrical / Roll Methods: Used for printing on rounded containers like tubes or bottles—mesh or substrate moves in rolls or cylinders.

2. Screen Printing Process: Step by Step

The typical screen printing workflow for packaging decoration includes:

1. Design Preparation: Vector art or high-contrast blacks printed on acetate film for stencil creation.

2. Screen & Emulsion Setup: Stretch mesh over a frame, coat with UV-sensitive emulsion, then expose using artwork to create print stencil areas.

3. Development of Screen: Rinse off unexposed emulsion to form open mesh areas for ink passage.

4. Printing: Position container (jar, tube, tin, etc.), apply ink flood and pull squeegee across screen to transfer design through mesh.

5. Curing or Drying: Printed items are heat-cured or air-dried to solidify ink and ensure durability .

6. Clean-Up and Reclaiming: Wash off emulsion for screen reuse after print run; clean inks and tools .

3. Packaging Products Commonly Using Screen Printing

Screen printing is ideal for containers where durability, opacity, and branding are key:

• Glass & Plastic Jars: Perfect for bold logos, product detail, and high-opacity decoration.

• Metal Tins & Tubes: Spot colors, metallic inks, or raised ink on curved surfaces produce premium effects.

• Pre-Roll Tubes / Vape Tubes: Cylindrical screen printing methods ensure brand messaging wraps cleanly around round packaging.

• Flexible Bags: Mylar or paper-based pouches benefit from screen printing for high-contrast branding and regulatory info.

• Caps & Lids: Even small surfaces (caps, lids) can feature spot-printed logos or dosage markings.

4. Pros & Cons of Screen Printing

Advantages:

• Excellent color opacity and durability

• Great for non-flat surfaces and odd geometries

• Lower cost for small-to-medium runs

• Textured ink layers add tactile appeal

Disadvantages:

• Less efficient for high-volume print runs compared to flexo or digital

• Each color requires its own stencil and screen

• Setup and color registration can slow multi-color jobs

5. Why Choose Archibald’s Screen Printing for Packaging?

At Archibald, we integrate screen printing into our full-service packaging solutions, offering:

• Custom Printing Options: Spot color, halftone, duotone, or simulated process prints.

• Material Matching: Printing on glass jars, plastic bottles, tins, tubes, and bags with optimal ink and mesh.

• Special Effects: Raised ink, metallic finishes, soft-touch coatings, and security codes.

• Regulation-Ready Labels: Printable areas for compliant dosing labels, graphics, QR codes, and batch info.

• Flexible Quantities: From small launches to mid-size batches, quick turnaround with consistent quality.

Want screen printing on your packaging? Visit our catalog to explore custom screen-printed jars, tins, tubes, and bags. Contact us today to request samples or place a quote — let us help your brand make a bold mark.