Rotary Screen Printing

Rotary screen printing uses cylindrical nickel screens with engraved patterns that rotate continuously as fabric passes beneath, enabling high-speed production of printed textiles. This method has become the dominant technology for large-volume textile printing, combining speed, consistency, and cost efficiency for production runs measured in thousands of meters.

The process begins with creating cylindrical screens, typically made from thin nickel with precisely etched openings that form the design pattern. Each color in the design requires a separate screen. During printing, the fabric moves continuously beneath the rotating screens while ink or paste is pumped inside each cylinder. A squeegee or blade inside the screen forces the colorant through the pattern openings onto the fabric below. The printed fabric then passes through drying and fixation stages appropriate for the ink type used.

Rotary screen printing achieves production speeds up to 100 meters per minute, making it highly efficient for large orders. The continuous process ensures consistent quality throughout the production run, with precise color registration between multiple screens. Once screens are prepared and the machine is set up, the cost per meter decreases significantly with volume, making rotary printing economically advantageous for large production quantities. The technology handles all-over patterns and repeating designs with excellent consistency.

The method does have limitations that make it less suitable for certain applications. Initial setup costs are substantial, including screen preparation for each color. Minimum order quantities are typically required to justify setup expenses. Designs must work within repeat pattern constraints determined by screen circumference. Screen costs accumulate with each additional color in the design. Rotary screen printing is the standard choice for bedding prints, curtain fabrics, apparel textiles, and home textile products where production volumes justify the setup investment.