For anyone in screen printing, productivity isn’t just a goal; it’s a necessity. Time saved means money earned, and doubling productivity can make an impressive difference to your bottom line. One way to supercharge efficiency is by running your screen printing presses in tandem. This method transforms a series of individual tasks into a seamless team effort, allowing you to work smarter, not harder.
Ready to learn how? Here’s everything you need to know to set up a tandem printing system that keeps your team in sync, maximizes output, and keeps bottlenecks at bay.
What Exactly is Tandem Printing?
In a traditional screen printing setup, each printer operates their own press independently, which works well for smaller, simpler jobs. But what happens when you need to handle larger orders or multi-placement designs (like front, back, and sleeve prints)? Solo setups start to feel limiting — and this is where tandem printing shines.
Tandem printing means running two or more presses together in a coordinated sequence with multiple people, each responsible for a specific task in the workflow. Instead of each printer racing to finish their part, tandem printing aligns them to work as a team, with every movement and task flowing into the next.
Here’s the typical tandem printing setup:
- Press A: The first person loads the garment, pulls the print, and sends it down the line to Press B.
- Press B: The second person takes over, applying the next placement or detail.
- Catcher: At the end of the line, the final person catches the shirt, performs a quick quality check, and packages it.
This setup not only speeds up production by dividing tasks but also allows for better quality control and even reduces fatigue by focusing each team member on a specific role.
Why Teamwork is Essential in Tandem Printing
With tandem printing, individual work gives way to a team effort. In solo printing setups, printers often race against the clock or even compete with each other. But tandem printing isn’t about beating the clock or your teammate — it’s about syncing up to create a unified workflow.
Imagine the process as a dance: each person moves at a steady, sustainable rhythm, passing the garment to the next person without missing a beat. The person on Press A sets the initial pace, known as the dwell time (more on that in a bit), and this pacing sets the tone for the whole team.
It’s also important to check in with each other. Regular communication prevents potential slowdowns and helps catch issues before they become problems. Encouraging open feedback throughout the shift allows the team to adjust pace if needed, so everyone stays comfortable and productive.
Setting the Right Dwell Time
In tandem printing, setting the correct dwell time is key. Dwell time refers to the time a shirt stays at each station before moving to the next. Think of it as the heartbeat of the production line: if it’s too fast, team members can become overwhelmed; if it’s too slow, productivity drops.
To find the right dwell time:
- Start with the Slowest Task: Identify the task in the line that takes the most time. If loading and pulling a print on Press A takes 12 seconds, but Press B’s work takes 15 seconds, you’ll want to set the dwell time closer to 15 seconds.
- Test and Adjust: Run a test batch to see if the dwell time feels right. Adjust as needed until each team member has a comfortable pace.
A Tip for Maintaining Flow
If you find that Press B or the catcher is slightly behind, the person on Press A can briefly pause, allowing everyone to catch up. During this pause, the Press A operator can even lay down ink for Press B or prepare additional screens. This helps maintain a smooth, continuous flow without creating backups.
By finding the ideal dwell time, you create a system where every person can work comfortably without feeling rushed or overwhelmed.
How Tandem Printing Halves Production Time
One of the most noticeable benefits of tandem printing is that it significantly reduces production time. Here’s how it works:
In solo setups, each printer handles every placement on a shirt — the front, back, and sleeves, for example. For a large order, this means multiple passes for each garment, each time reloading and repositioning it. With tandem printing, however, you cut these steps down by dividing the tasks between team members.
Let’s look at an example: if you’re working on a 500-shirt order with three placements (front, back, and sleeve), each shirt would need three passes on a single press. With tandem printing, you split up these tasks, allowing each placement to happen in sequence without reloading. This effectively halves the production time by minimizing the number of touches per garment.
The result? More shirts in less time, with everyone working on a specific task rather than the entire process.
Quality Control with Multiple Eyes
Tandem printing’s team approach also introduces a built-in quality control advantage. Instead of relying on a single person to catch every defect or error, tandem printing creates multiple checkpoints as the garment moves down the line.
Here’s how quality control works in tandem printing:
- Press A Operator: They’re the first to spot any issues with loading, ink, or placement.
- Press B Operator: They see the garment with fresh eyes, making it easier to notice any flaws or ink smudges the first person may have missed.
- The Catcher: This final checkpoint is responsible for checking alignment, color consistency, and other quality aspects before the garment goes to packaging.
Real-Life Scenario: Say the ink starts looking lighter partway through a run. In a solo setup, this might go unnoticed until it’s too late. But in tandem printing, the Press B operator might spot this early on, allowing the team to address the issue right away, saving time, resources, and customer satisfaction.
A Flexible Setup Minimizes Waste
An added benefit of tandem printing is its flexibility in setup. For maximum efficiency, we here at Kaizink place our dryers on wheels, making it easy to arrange them based on the specific job. Here’s why that matters:
- Minimizing Motion: By setting up our job to minimize unnecessary movement, team members stay in one spot, focusing on loading and unloading without wasting time walking or moving back and forth.
- Customizing Layout for Different Jobs: Each job has its quirks, whether it’s the size of the garment, the number of placements, or ink complexity. Being able to adjust the layout means you can arrange the dryers to fit each unique requirement, ensuring no motion or time is wasted.
Imagine working on oversized hoodies, which take up more space than T-shirts. With dryers on wheels, you can easily spread them out to make handling easier and keep the workflow smooth.
Maximizing Multi-Placement Printing
In addition to speeding up production, tandem printing is ideal for handling jobs with multiple placements on a single garment. Say you’re printing a logo on the front, a secondary design on the back, and perhaps a sleeve print as well. With solo setups, you’d need to reload the garment for each placement. Tandem printing, however, allows each team member to focus on a specific placement in sequence, creating a continuous flow and reducing the time required per shirt.
For high-volume, multi-placement jobs, tandem printing is a game-changer. You not only reduce the time required but also improve consistency, as each team member focuses on a single placement.
Why Isn’t Tandem Printing More Common?
Despite its advantages, tandem printing is still relatively uncommon in many small to medium-sized screen printing shops. Here are some of the reasons why:
- Change from Traditional Methods: Many print shops follow a solo printing model because it’s how they’ve always done things. Transitioning to a team-based workflow can seem daunting, and not every shop wants to make that shift.
- Coordination Requirements: Tandem printing requires a team that communicates well and works seamlessly together. For some shops, finding the right combination of people or investing in training and coordination may not seem practical.
- Space Constraints: Not every shop has the floor space for multiple presses to run in tandem. Smaller shops with limited space may find it challenging to arrange presses in a way that works for tandem printing.
In larger operations where high output is critical, tandem printing is often a go-to solution for maximizing productivity. However, for smaller shops or those with limited resources, a traditional solo setup may feel more manageable — even if it’s not as efficient.
Potential Drawbacks of Tandem Printing
While tandem printing offers plenty of benefits, it’s not without its challenges. Here are a few potential drawbacks to keep in mind:
- Communication is Essential: Since tandem printing relies on teamwork, any miscommunication can create bottlenecks. If team members aren’t in sync, it slows down the entire process.
- Risk of Overwhelming the Catcher: If the pace isn’t steady, the final person (catcher) may struggle to keep up, which can result in pileups and stress.
- Difficulty Adjusting Dwell Time for Different Jobs: Some jobs require more time per placement, and adjusting dwell time for each order may require frequent recalibration.
Step-by-Step Guide to Starting with Tandem Printing
If you’re ready to give tandem printing a try, here’s how to get started:
- Assemble Your Team: Choose team members who communicate well and can adapt to a coordinated workflow.
- Set Up the Press Layout: Arrange the presses for minimal movement and easy handoffs. If possible, place presses on wheels to allow flexibility for different jobs.
- Establish a Comfortable Dwell Time: Find a pace that allows each person to work steadily without feeling rushed.
- Run a Test Batch: Start with a small run to test the flow, and adjust the setup as needed.
- Encourage Open Feedback: Regular check-ins allow the team to stay aligned, addressing any issues early.
Final Thoughts: Why Tandem Printing Might Be Right for You
Tandem printing offers an efficient, collaborative workflow that can double productivity while improving quality control. By creating a steady, comfortable pace, each team member can focus on their role, reducing fatigue and enhancing consistency. If you’re looking to speed up production, handle larger orders, and improve team morale, tandem printing might just be the upgrade your shop has been waiting for.
