Screen Print LARGE Hat Orders...Fast!

One of the most important factors in any production industry is TIME. There never seems to be enough of it no matter how well we plan, and it can drastically affect the outcome of completing an order if it starts to get in the way. And, with items like hats that are bulky and do not lay flat on their own, decorating these items can prove challenging due to the time it takes to set them up for printing, and resetting them after each run. But have no fear, the solution to your productivity dreams is here, and it exists in the form of the Captain Platen Kit Four Station. And the best part? It works on the machine you already have.

For this project, we are fulfilling a large hat order for a client, consisting of a two-color design on unconstructed baseball hats. And, we will be displaying three different types of production methods so that you can utilize the one that works best for your print shop!

Setting Up the Screen Print Station

  1. Start by removing all t-shirt platen bases from your screen printing station and replacing them with the Master Brackets included in your Kit
    • Install the Master Bracket by sliding it into place on the station (arm) and screw in the side knob first, then the bottom knobs. Repeat this for each station.
  2. Place a Captain Platen SP on each Master Bracket

Loading the Captain Platen SP

  1. Place your Captain Platen SP on the Master Bracket with the Top Plate closest to you and the locking bar pushed up and away from you and lock the platen in place by pushing the platen's side knobs inward.
  2. Undo the back straps of the hat and slide the hat brim under the front bar.
  3. Tuck the sweatband, any tags, and all inner layers underneath the Top Plate and pull the hat toward you until it is laying flat, ensure the top of the hat brim is aligned with the top of the platen and the sides of the brim are aligned with the sides of the platen.
  4. Pull the hat's front panels taut and engage the locking bar by pulling it back toward you and locking it in place under the Top Plate. 
  5. Tug at the sides of the front panels to get the surface as flat as possible.
  6. Now the hat is ready for printing!

Print Method 1: Best for Small to Mid-Size Print Shops

This method flows as follows:

  • Load each Captain Platen with a hat
  • Print each hat
  • Unload each hat
  • Cure the hats on a conveyor dryer
  • Repeat

KEY TIP: If you are printing a multi-color design like we are in this project, set up a flash cure over one print station so that after you print the first color, when you move to the next station, that first color will cure to be dried down enough for the next color.

Print Method 2: Best for Mid-Size Print Shops

  • Pre-load each Captain Platen on the Setup Station included in your kit
  • Place each loaded Captain Platen on to each screen print station
  • Print and flash cure each hat
  • Unload
  • Cure the hats on conveyor dryer
  • Repeat

KEY TIP: The most efficient way to utilize this print method is by designating one person or team to pre-load the Captain Platens while another person or team prints.

Print Method 3: Best for Mid to Large Print Shops that Function in a Fast-Paced Production Setting

  • One person or team loads each Captain Platen on each print station as it is passed to them
  • One person or team prints the hats on each station as it is passed to then
  • The first team then unloads the printed hat and sends it through the conveyor dryer for curing and reloads the next blank hat
  • Repeat

Screen Shot 2021-10-14 at 2.53.48 PM

With these tried-and-true processes, you WILL have the job done, efficiently, in no time!

Now what are you waiting for? Check out what else you can do with your Screen Printing Kits here!

Products Used in this Project:

Captain Platen Kit Four Station

Want to See More of These Products in Action? Schedule a Demo Session with Us!

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