Introduction

Rotary screen printing is one of the most widely used textile printing technologies in the global apparel and home textile industry. Known for its high production speed, consistent quality, and cost efficiency, rotary screen printing plays a crucial role in mass production, especially for fabrics like cotton, polyester, viscose, and blends.

Rotary-Screen-Printing

Despite the rise of digital textile printing, rotary screen printing remains the industry backbone for large-volume orders due to its lower cost per unit and excellent color penetration. This article provides a complete guide to rotary screen printing, covering the process flow, machinery, advantages, limitations, and detailed profit calculation, making it ideal for factory owners, merchandisers, textile engineers, and entrepreneurs.

 

What Is Rotary Screen Printing?

Rotary screen printing is a continuous printing process where cylindrical screens rotate in synchronization with fabric movement. Each rotating screen applies a specific color of paste through engraved openings onto the fabric.

Unlike flatbed screen printing, rotary printing allows non-stop fabric feeding, making it ideal for bulk production.

 

History and Evolution of Rotary Screen Printing

Rotary screen printing was introduced in the 1960s as an improvement over flat screen printing. The innovation of nickel rotary screens allowed faster speeds, better registration, and longer print runs.

Over time, advancements such as:

• Laser-engraved screens
• Automatic color kitchens
• Magnetic squeegees
• Digital design integration

have significantly improved productivity and print accuracy.

 

Rotary Screen Printing Process (Step-by-Step)

1. Design Development

Designs are created using CAD software like:

• NedGraphics
• Photoshop
• Illustrator

Each color in the design is separated into individual layers.

 

2. Screen Engraving

Rotary screens are engraved using:

• Laser engraving
• Chemical engraving

Screens are typically made of nickel mesh with mesh counts ranging from 40 to 195 depending on design detail.

 

3. Fabric Preparation

Fabric preparation is critical for quality output and includes:

• Desizing
• Scouring
• Bleaching
• Heat setting (for synthetics)

Proper preparation ensures better dye fixation and color sharpness.

 

4. Color Paste Preparation

Color paste consists of:

• Dyes or pigments
• Thickener
• Binder (for pigment printing)
• Chemicals and auxiliaries

Modern factories use automated color kitchens for accuracy and consistency.

 

5. Printing Operation

• Fabric moves continuously under rotating screens
• Each screen prints one color
• Squeegee pressure pushes paste through engraved areas
• Printing speed: 30–80 meters per minute

 

6. Drying and Fixation

Fixation methods depend on dye type:

• Steam fixation for reactive & disperse dyes
• Heat curing for pigment printing

 

7. Washing and Finishing

Post-print washing removes:

• Unfixed dyes
• Chemicals

Finishing improves:

• Hand feel
• Color fastness
• Fabric appearance

 

Rotary Screen Printing Machines

Main Components of a Rotary Printing Machine

1. Fabric feeder
2. Rotary screens
3. Squeegee system
4. Color supply system
5. Dryer
6. Control panel
7. Fabric delivery unit

 

DTG vs DTF Printing – Which Is Better for a Profitable Business?

Types of Rotary Screen Printing Machines

1. Magnetic Rotary Printing Machine

• Precise squeegee control
• Less screen damage
• Widely used in modern mills

2. Traditional Rotary Printing Machine

• Manual adjustments
• Lower initial cost

 

Popular Rotary Printing Machine Brands

• Stork Prints (SPG Prints)
• Reggiani
• Zimmer
• Buser
• A.T.E
• MS Printing Solutions

 

Types of Rotary Screens

Screen Type	Mesh Count	Application
Coarse	40–60	Bold designs
Medium	80–125	General printing
Fine	155–195	Detailed patterns

 

Advantages of Rotary Screen Printing

1. High Production Speed

Capable of printing 10,000–25,000 meters per day per machine.

2. Cost-Effective for Bulk Orders

Lower cost per meter compared to digital printing.

3. Excellent Color Penetration

Deep, vibrant shades especially for reactive printing.

4. Long Print Runs

Ideal for repeated designs and large orders.

5. Consistent Quality

Uniform color application throughout production.

 

Limitations of Rotary Screen Printing

1. High Setup Cost

Screen engraving and machine setup increase initial cost.

2. Not Suitable for Small Orders

Uneconomical for short runs due to setup expenses.

3. Design Change Takes Time

Changing designs requires new screens.

4. Environmental Concerns

High water and chemical consumption if not optimized.

 

Rotary Screen Printing vs Digital Printing

Feature	Rotary Printing	Digital Printing
Setup Cost	High	Low
Production Speed	Very High	Medium
Best For	Bulk orders	Small runs
Cost per Meter	Low (bulk)	High
Color Limitation	Screen-based	Unlimited

 

Cost Breakdown in Rotary Screen Printing

1. Fixed Costs

• Machine depreciation
• Factory rent
• Labor salary
• Utilities

2. Variable Costs

• Screens
• Dyes & chemicals
• Power & water
• Fabric wastage

 

Profit Calculation Example (Per Day)

Assumptions:

• Daily production: 15,000 meters
• Printing charge: $0.45/meter
• Operating cost: $0.30/meter

 

Daily Revenue

15,000 × $0.45 = $6,750

Daily Cost

15,000 × $0.30 = $4,500

Daily Gross Profit

$6,750 – $4,500 = $2,250

 

Monthly Profit (26 working days)

$2,250 × 26 = $58,500

(Profit may vary based on design complexity, dye type, and efficiency)

 

How to Increase Profit in Rotary Screen Printing

1. Optimize screen reuse
2. Reduce paste wastage
3. Use automated color kitchens
4. Improve machine efficiency
5. Invest in skilled operators
6. Implement water recycling systems

 

Sustainability in Rotary Screen Printing

Modern rotary printing mills adopt:

• Low liquor ratio washing
• Eco-friendly dyes
• Water recycling plants
• Energy-efficient dryers

These steps reduce environmental impact and operating costs.

 

Applications of Rotary Screen Printing

• Apparel fabrics
• Bed sheets & pillowcases
• Curtains
• Upholstery
• Scarves
• Towels

 

Future of Rotary Screen Printing

Despite digital printing growth, rotary screen printing will remain dominant for mass production. Hybrid models combining rotary + digital are becoming popular for flexibility and efficiency.

 

Conclusion

Rotary screen printing remains one of the most profitable and reliable textile printing technologies for large-scale production. With proper machine selection, skilled manpower, and cost control, factories can achieve high productivity and strong profit margins.

For textile entrepreneurs and factory owners, rotary screen printing continues to be a long-term investment with stable returns, especially in countries like Bangladesh, India, China, and Vietnam.