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MUG PRINTING METHODS

Direct Screen Printing:

Ideal for: earthenware, cost effective in both large and small runs; can be used on bone china

Not for: complex half tones

An image, usually up to four solid colours, is printed within a given area directly onto the rotating body of the mug. The method is used when:

· The design is simple

· There are no complex half tones although some half tones can be directly printed

· The registration is not over demanding

· The design is not required to be larger than the print area.

There are limitations with this process and it is primarily used for the low budget side of the earthenware market. A direct printer can print several thousand items a day, in contrast to the slower, hand decorated transfer process.

Transfer Printing:

Ideal for: earthenware and bone china; more complex art tones; critical registration and full colour work; printing on the full surface area of the item; highly-shaped items

The design is silk-screen or litho printed onto special paper, then cover-coated. The resulting print is then treated as a water slide transfer and applied by hand to the ware. The process is slower and more labour intensive than direct screen printing but is more flexible with colours able to be built up with precision and control. Printing is possible on the full size of a mug, inside on the base, as a back stamp, or just inside the rim.

Transfer or litho printing, as opposed to direct silk-screen, is used when:
• larger than average print is needed
• working with bone china
• printing in four-colour process
• cases where more than four line colours, very fine detail or tight registration is required.

Digital Printing:

Ideal for : photo images or cartoon images without bright primary colours; both earthenware and bone china; small print runs.

Not for: any images with strong primary colours or coloured glazed ceramics.

An image is printed directly to a specially coated paper in process colour, using technology similar to an office laser printer. This is then cover-coated, becoming a water slide transfer which is applied to the ware. There are no screen costs, just an origination charge when the design is finalised. You can have one print or hundreds. As with full colour printing, there are limitations on the strengths of reds and pinks but, with pastels and citrus shades, the results are excellent. Because the inks are a natural product, perfect colour matching cannot be achieved on repeat orders and it is not possible to match the primary colour chart, but the technique is excellent for photographic reproduction.

Dye Sublimation

Ideal for: whatever colours you want; full colour image; stunning photographic reproduction; small order flexibility; fast turnaround

Not for: certain mug shapes; mugs that need to withstand frequent harsh dishwasher cycles

Dye sublimation enables really accurate colour photographic reproduction.
A four-colour high quality photo finish is possible with crystal clear results and really bright impact colours. The technique uses organic colour dyes. This opens up a much more diverse colour spectrum and gives you a brilliantly outstanding gloss appearance. It is also environmentally friendly, avoiding the use of substances such as lead and cadmium. Because it does not have to withstand a kiln firing, it provides a more versatile colour range than fired enamel colours.

Dye Sub Heat Change Mugs

Ideal for: an eye-catching and distinctive promotion tool; earthenware

Not for: mugs that need to be dishwasher or microwave safe; bone china

The mug is a standard Durham mug, which is then spray coated with a heat-change colour and printed with a dye sublimation image using organic colour. The result is a real talking point as the printed image literally comes to life before your eyes when a hot drink is poured in. We have two stock heat change coating colours. These mugs are great for promotions or simply reinforcing business relationships. Maybe your staff and clients are ‘the hottest team in the business’? Why not reward them with their very own special ‘heat change’ slogans to leap out at them every time they fill their mug. The organic colour is cured into the spray coating, unlike ceramic colour, which is fired into the glaze. Hence the need to avoid dishwasher or microwave use

Four Colour Printing

Ideal for: large run photographic work

Not for: smaller runs which are now better suited to dye sub or digital printing

The image is broken down into four essential colours – cyan, magenta, yellow and black (known as CMYK). Most creative software can store an image in CMYK format, but be careful as the monitor may not give a Pantone-accurate version of the image. It is best to send graphic files with a printed visual. Note that the magenta is not as strong as in paper printing, limiting the strength of reds and pinks. This can be overcome by using spot colours from extra screens. Additional spot colours are recommended to highlight text such as slogans or product names.

Special Processes:

3D:

Ideal for: character merchandising; earthenware; all sizes of mug

Not for: runs below 1500

3D can make your message literally stand out. Technically speaking, it is not printing but the placing of moulded or shaped clay onto the surface of the mug prior to glazing. Colour is then added using using transfer prints placed onto the beaker surface and the added clay. The minimum run for 3D is 1500. Artwork should be supplied as a vector/line image as a single colour separation.

Laser Etching:

Ideal for: something distinctive and different; earthenware; larger mug sizes

Not for: runs below 1500; bone china

Laser etching results in an embossed image ‘carved’ into the glaze of an earthenware beaker, exposing the white clay biscuit of the mug. This gives the product a tactile as well as a visual appeal. After the etching process, the ware is fired at a very high temperature to render the biscuit non-porous, preventing the absorption of contaminants through the exposed surface.
The minimum run for laser etching is 1500. Artwork should be supplied as a vector / line image as a single colour separation.

Embossing:

Ideal for: designs such as motifs; shields and heraldry that require a raised mark

Not for: print methods other than direct or transfer printing

An exclusive print technique to Keramikos. It can be used on any of our direct printable shapes. A special paste is initially printed which is overprinted with shiny gold or silver. Where the gold or silver hits the paste the colour will appear matt and stand slightly proud.

Iridescent:

Ideal for: designs such as motifs; shields and heraldry that require a raised mark

Not for: print methods other than direct or transfer printing

An exclusive print technique to Keramikos. As many as five metallic colours are placed on a direct screen at one time. As the squeegee is passed over the screen the colours mix and swirl together to give each print and mug a unique appearance. No two mugs are identical. Due to the amount of colour being passed through the screen we would recommend this process for smaller runs only.

Frosted:

Ideal for: bold print areas that maximise the effect; can be used on both earthenware and bone china

Not for: fine text; items that will get heavy wear; transfer printing (direct printing only)

A light catching frosted effect is produced by adding fine glass particles on to a special gum on the surface of the ware. During firing, the glass particles start to melt into each other giving a textured finish. This ice-like crystal layer is overprinted onto the screen-printed colours. Not dishwasher or microwave safe.

FINISHING TOUCHES:

Handles

Ideal for: decorative items; adding a touch of class and elegance to earthenware, bone china or glass

Not for: precious metals gilding for everyday use items

Handle Flashes. Handle flashes are produced by a single brush stroke along the width of a handle. This hand finished touch adds a special character to the product. It can be done using precious metals or colour.

Gilding

Ideal for: decorative items; adding a touch of class and elegance to earthenware, bone china or glass

Not for: precious metals gilding for everyday use items

Gilding. A precious metal gilded rim on bone china has always promoted quality and value. Used with earthenware, precious metal gilding can enrich a design. There are different grades of gilding, from a whisper-thin halo through to broad bands, giving options to suit all tastes and designs. Applied to a dinner plate, it can help frame images and designs. The effect is to gain a touch of brilliance.

Ceramic Banding

Ideal for: decorative items; adding a touch of class and elegance to earthenware, bone china or glass

Not for: precious metals gilding for everyday use items

Banding. The addition of a coloured band to the rim of a beaker or a coaster, particularly a colour at the heart of the surface decoration, imparts style to what may seem an ordinary design

Glass Banding

Additional to the printed design we can add a coloured band to the rim of the glass to add more definition to the edge. This often looks best using a colour from the surface design. This process is done by hand.

It is also possible to gild the rim in gold or silver. Gilding adds value and an extra air of quality. Note, gilding is not ideal for items that will receive heavy use

Government Measures

If the glassware is to be used in licensed premises, and metered measures are not used, every glass must be stamped with the CE mark and number to verify the measure given, this is called government stamping. This is done as a special order and minimum quantities may apply.

Inside Print

Ideal for: brand reinforcement and distinctiveness; individuality; exclusiveness; practicality

Not for: dye sublimated, heat change or lustre mugs

Inside print is the application of print inside the mug or cup. Used creatively, it can cleverly reinforce your brand or message by drawing the eye to it as the liquid goes down. Indeed, because it is achieved by adding a transfer, any surface can be decorated so there are also options, for example, for adding a telephone number or name to a handle.

Backstamps

Ideal for: brand reinforcement and distinctiveness; individuality; exclusiveness; practicality

Not for: dye sublimated, heat change or lustre mugs

Backstamps are prints on the outside base of the mug. They can be used to put individual numbers on a limited edition run or adding words, such as ‘bone china’, to reinforce the value of the item.