Tips for Estimating and Reducing DTF Printing Costs

Direct-to-Film (DTF) printing has gained popularity among small printing businesses due to its easier setup, faster turnaround times, and unparalleled color representation. However, the upfront investment and ongoing printing costs are significant factors in determining whether DTF printing is the right choice for your business.

In this passage, we will delve into the related consumption and costs of DTF printing and explore effective ways to minimize them.

Written by Procolored - Published on Oct 8, 2024

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Written by Procolored - Published on Oct 8, 2024

PASSAGE SUMMARY

1. How to Estimate DTF Printing Cost
1.1 DTF Printing Cost Breakdown
1.2 Cost Calculation
2. Ways to Reduce DTF Printing Cost
2.1 Choose the Cost-Efficient Products
2.2 Reduce Waste

Title

1. How to Estimate DTF Printing Cost

1.1 DTF Printing Cost Breakdown

First, let's review the DTF printing process:

①

Confirm graphic design

on computer

④

Use an oven to

cure the powder

②

Apply DTF printer to

print out the graphic

⑤

Heat press the graphic

onto fabrics

③

Spread adhesive

powder on graphic

⑥

Peel off the

graphic film

①

Confirm graphic design

on computer

②

Apply DTF printer to

print out the graphic

③

Spread adhesive

powder on graphic

④

Use an oven to

cure the powder

⑤

Heat press the graphic

onto fabrics

⑥

Peel off the

graphic film

Through the printing process, it is relatively straightforward to identify all the related costs involved in completing a DTF print. Generally, these costs can be broken down into the following categories:

Printing Costs: This includes expenses related to the consumption of inks, films, and adhesive powder.

Equipment costs: These costs consist of two main components: the initial purchase of equipment and ongoing maintenance.

Fabric costs: This refers to the cost of the blank items, such as t-shirts, hoodies, caps, and other garments or materials.

Other costs: This category includes expenses related to waste printing, power consumption, and labor during the printing process.

1.2 Cost Calculation

To better understand how to estimate DTF printing cost, let’s use some real values.

Printing cost = $0.25(ink) + $0.7(film) + $0.15(powder) = $1.1

Ink cost: Auusming the printed graphic is A4 letter size, a 1000ml ink bottle prized at $100 can support an average of 400 prints. This means each print consumes 2.5ml of ink, which is valued as $0.25.

Film Cost: For a sheet-fed printer, 100 sheets of printing film cost $0.7 per sheet.

Powder Cost: A standard A4 letter-size print typically requires 1.5 grams of adhesive powder. With a 1000-gram bag of powder costing $100, the powder cost for each print comes to $0.15.

Equipment cost = $1.15(product) + $0.25(maintenance) = $1.4
Product purchase: A conservative estimate for the acquisition of an A4 Direct-to-Film (DTF) printer, along with an oven and a heat press, is approximately $3,000 in total.
The cost attributed to the equipment per t-shirt can be significantly influenced by the lifespan of the machines and the printing schedule. If we assume that all the machines will function well for one year, which consists of 52 weeks, and if we plan to print around 50 t-shirts (each with an A4 letter-sized print) per week, then the product cost per shirt would be calculated as follows:

Total Equipment Cost: $3,000; Number of Weeks in a Year: 52; T-Shirts Printed Per Week: 50

Total Equipment Cost = $1.15=$3,000/52 weeks/50 t-shirts.
Maintenance cost: For the machines to operate smoothly over the course of a year, regular maintenance is essential, particularly for the digital printer. We are assuming that the printer will need a printhead replacement twice a year, with each replacement costing $320. The maintenance cost per t-shirt can be calculated as: $0.25=$640/52 weeks/50 t-shirts.

Fabric cost = $3
For the purposes of this example, we are considering a T-shirt. The price of a T-shirt can vary significantly based on the type of fabric and design. When sourcing from wholesale platforms such as Alibaba, a T-shirt that meets the necessary quality standards can be obtained for approximately $3 each.

Other cost: 20%
This category encompasses various expenses such as printing waste, human labor, and utility costs. To account for these factors, we will add a 20% surcharge to the total printing cost.

To sum up, conservatively estimated, the cost of per custom shirt would be $6.6 = ($1.1+$1.4+$3)*120%

Indeed, this breakdown and calculation provide a somewhat idealized scenario, as real-world operations often encounter various factors that can affect costs. In practice, there may be fluctuations due to different printing habits, unexpected maintenance, variations in material prices, and other unforeseen circumstances. Nevertheless, this estimation can serve as a useful reference for roughly calculating the printing cost, which can help in personal budgeting or setting business pricing.

2. Ways to Reduce DTF Printing Cost

2.1 Choose the Cost-Efficient Products

Choosing cost-efficient products can significantly help in reducing expenses, especially in product maintenance. Here are some details to consider for maximizing cost efficiency:

More reliable and stable performance: When it comes to selecting a printer, reliability and stability are crucial for minimizing maintenance costs and ensuring consistent performance. Many printers on the market use a peristaltic (squeezing) circulation system for ink supply. While this system is common, it can accelerate the aging of ink pipelines, leading to more frequent clogging issues. This not only disrupts production but also increases maintenance and replacement costs.To address these issues, consider investing in new printers that feature advanced ink circulation systems.

Higher efficiency: Incorporating automated machines into your DTF (Direct-to-Film) printing workflow can significantly enhance efficiency and reduce overall printing costs. Here’s how automatic machines, such as a powder shaker and a smart heat press, can benefit your operation.

Attentive customer service and tech support: Improper (dis)assembly, operation, or repairs can lead to unexpected damage to your DTF printing equipment, which can increase maintenance costs and downtime. To mitigate these risks, it's essential to have attentive customer service and technical support.

2.2 Reduce Waste

Choose small graphic for color test: Some printer users prefer to print a color test before starting their everyday printing plan, which inevitably consumes ink and film. Choosing smaller graphics for the color test can help save on printing consumables while still ensuring an effective color reference.

Perform regular maintenance and calibration: Daily or regular cleaning of machine components such as the printhead, waste ink collector, and capping station helps avoid interrupted prints caused by nozzle clogging. Daily or regular calibration of the printer's color space, working temperature, and humidity helps alleviate color deviation in the printing outcome, lowering the printing deficiency rate.

Apply genuine consumables only: Most DTF printer brands offer compatible consumables like ink, film, and adhesive powder, which are developed and designed to work together. For example, the specified ink drying time is tailored to match the printer’s printing speed, and the specified ink viscosity is suited to the film surface. Using genuine and compatible consumables can ensure higher reproduction quality, especially for intricate graphics.

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