Mimaki and the power of DTF printing

Marc Verveem, Product Manager EMEA from Mimaki Europe, discusses the cost efficiencies and sustainability benefits of direct-to-film (DTF) printing.

What are the benefits of DTF printing? 

DTF printing offers numerous advantages over traditional methods. It eliminates the time-consuming process of plate creation in screen printing and the tedious weeding [removal of excess vinyl] required in traditional vinyl heat transfer. Additionally, DTF technology enables the creation of vibrant designs due to its full-colour printing capabilities. 

For Mimaki, venturing into DTF technology represents an exciting expansion into a new market segment. The decision to pursue this path was driven by our confidence in providing a market-leading solution leveraging our core technologies and the technical prowess of our digital printers in the textile portfolio. There’s a clear market demand for a stable, reliable DTF printing solution, where support from a trusted partner with dependable aftercare is crucial. Mimaki's reputation for exceptional support ensures that DTF customers receive assistance every step of the way.

What is the minimum of run lengths that make DTF printing cost-effective?

This is dependent on the type of DTF business, rather than on the production volume. For instance, businesses that solely print and sell DTF stickers experience lower profits due to labour-intensive work and the various costs associated with sticker production.

Consequently, a higher production volume is necessary to achieve cost-effectiveness. In this scenario, profit margins are narrower, necessitating a continuous flow of orders to maintain cost-effectiveness. 

Conversely, selling finished products such as t-shirts can be highly lucrative, with DTF printing technology offering significantly higher profits and advantages due to the lower production and labour costs.

Marc Verbeem, Mimaki 

How many pieces of print do you need to do before the new machine pays for itself?

This again is dependent on the type of DTF business and will vary from business to business. Using the sticker and t-shirt analogy again, assuming the same profit margins and aiming to recoup the printer's cost within 12 months, reveals that the sticker-only DTF business needs to produce almost 400 stickers monthly to achieve this goal. On the other hand, the t-shirt DTF business achieves the same objective by producing 130 shirts per month. However, these figures are variable and depend on factors such as the print quality and purchase prices of consumables like DTF film and powder.

Is there a limit to DTF’s breadth of applications now or in the future? 

Transfers are compatible with a variety of fabrics including acrylic, cotton, nylon, polyester, wool or blends, depending on the specific powder, film and transfer settings utilised. The range of compatible fabrics will expand over time, with developments in different films (e.g. metallic, flock, etc.) already being made.

How can DTF help sustainability/reduce waste? 

Our DTF technology contributes to sustainability efforts by increasing the recyclability of used consumables. The PHT50 ink is packaged in an eco-friendly container, consisting of 4% plastic and 96% recyclable cardboard, which can be recycled in accordance with local regulations. Additionally, the film used in DTF is recyclable as it does not retain any ink residue after transfer to the fabric.

Mimaki’s first direct-to-film inkjet printer, the TxF150-75, with a maximum printing width of 80cm

What are the cost efficiencies?

DTF printing offers notable cost-effectiveness advantages over conventional screen printing. Unlike conventional screen printing, which involves the laborious process of plate creation, DTF printing eliminates this time-consuming step, thereby reducing production time and associated costs. Additionally, DTF technology excels in producing vibrant colours and intricate details often sought after in the promotional textiles and merchandising space.

When compared to DTG printing, DTF eliminates the need for pre-treatment typically required in DTG, saving on additional materials and labour costs. 

The ability to enter the amount of white ink required in the DTF software is another way in which it can significantly reduce cost over conventional screen printing.

How is DTF printing technology progressing in comparison with DTG and conventional screen printing?

DTF printing technology is definitely progressing as a viable alternative to DTG and conventional screen printing in the decorated apparel market, offering a combination of versatility, quality and efficiency that appeals to many printers. 

Aspects like the lack of time-consuming plate creation, ability to produce vivid and detailed prints, as detailed above, have made DTF a very attractive proposition, when compared to conventional screen printing, for printers working in the promotional and merchandising space for bespoke textiles.

Compared to DTG, DTF eliminates the need for pre-treatment and offers advantages in terms of printing on a wider range of fabrics, including dark coloured materials. Additionally, it can handle larger print runs more efficiently.

Visit Mimaki Europe at stand 12-F10 at FESPA Global Print Expo 2024, Europe’s leading print and signage exhibition, taking place from 19 to 22 March 2024 at RAI Amsterdam, Netherlands. Register here to visit.