Decoration transforms a raw blank garment into a branded artifact. However, choosing the incorrect decoration technique for a specific fabric weight or fiber blend can lead to cracking, peeling, or puckering. This guide explains how our decoration facility in Sialkot, Pakistan evaluates embellishment requests.
High-Density Puff Screen Printing
Puff printing involves blending a foaming agent into plastisol or water-based ink. When passed through a heated conveyor curing oven at approximately 160°C (320°F), the blowing agent activates, expanding the ink upward to form an elevated, rounded 3D relief on the garment surface.
- Best Applications: Bold typography, brand logos, and minimalist geometric artwork on 300+ GSM cotton fleece and heavyweight jerseys.
- Technical Constraint: Artwork line weight must be at least 2mm thick to allow the puff additive sufficient body to expand evenly without collapsing.
- Durability: Highly resilient when washed inside-out in cold water. Harsh hot cycles can degrade the expansion chambers over time.
Traditional & Discharge Screen Printing
Screen printing remains the gold standard for large-scale graphics, offering unbeatable wash-fastness and vibrant color reproduction:
- Plastisol Ink: Delivers sharp opacity and high color vibrancy on dark colored garments. Sits on top of the fabric fibers with a solid hand feel.
- Water-Based Ink: Penetrates the fiber structure directly, yielding a breathable, ultra-soft “zero-hand” finish favored by sustainable luxury brands.
- Discharge Printing: Formulated with a bleaching agent that replaces the garment’s original dye with ink pigment, allowing vibrant prints on dark 100% cotton without thick ink buildup.
Industrial Machine Embroidery & Chenille
Embroidery provides a three-dimensional, high-perceived-value finish that lasts the entire lifetime of the garment:
- Flat Tatami & Satin Stitch: Digital stitch mapping for clean logos and micro-lettering down to 5mm height.
- 3D Puff Embroidery: High-density EVA foam placed under the needle plate creates rigid, raised embroidery blocks common on luxury varsity jackets and headwear.
- Chenille Embroidery: Features looped yarn piles creating a plush, carpet-like vintage texture synonymous with varsity sportswear and collegiate heritage garments.
Selecting the Right Technique for Your Line
Rastify Gears operates computerized multi-head embroidery machines and precision manual and semi-automatic screen printing carousels under one roof. Our engineers test artwork proofs on actual production fabric swatches before approving bulk embroidery or screen creation.
