The water-based inks market in North America is expanding at a rapid pace, growing 5.9% from 2023 to 2024 alone—according to insights from The Business Research Company.

But why is water-based screen printing taking off right now, and what should you expect from the future?

The waves of customer demands, technological advancements, and the looming potential of environmental regulations are a few of the reasons brands choose water-based ink for their garments.

Today, our experts at Scrappy Apparel are here to share why water-based inks are gaining popularity and how you can choose the best screen printing ink for your brand.

Choose Scrappy Apparel for Your Screen Printing Project!

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What Is Water-Based Ink?

Water-based inks use water as their primary solvent to disperse pigment. Unlike plastisol, water-based ink deeply saturates the fabric, resulting in a softer print.

This is because the ink largely consists of soft resins and water, which evaporate throughout the curing process, enhancing the print’s texture and quality.

The main purpose of water-based ink is to replace plastic or polyvinyl chloride (PVC). As we mentioned, this change in our industry comes from the increasing demand for sustainable products.

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What Are the Benefits of Water-Based Ink?

Before we uncover the reasons behind the growth of water-based ink, we want to share the benefits it offers to customers:

• Eco-Friendly Choice – Water-based ink has no PVC or plastic components, making it the best choice for eco-friendly manufacturing.
• Softer and More Wearable Feel – There are no excess deposits of ink onto the fabric, and the ink blends seamlessly with the fibers. This results in soft garments with beautiful prints that won’t crack or peel.
• Free Flow of Air and Moisture – The ink enhances the fabric’s breathability by penetrating deeply into the material instead of forming a thick layer on the surface.
• Durable Colors – The ink is durable, long-lasting, and resistant to peeling and cracking, even after many washes.
• Accurate and Detailed Print – The ink creates images with exceptional detail, featuring sharper edges and more vivid colors. Your custom designs will look flawless.

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The Long-Term Potential of Water-Based Ink

Want to make the best investment in the long run? 

The forecast for water-based ink usage in the apparel market is more than just a trend. It represents a significant shift in consumer preferences and industry standards.

Growth Expectations

Water-based printing ink studies indicate that the market for water-based printing inks is expected to expand at a rate of 4% through 2025, followed by a growth rate of 3.5% leading up to 2030. 

North America continues to be a major consumer of water-based inks, thanks to the region’s shift toward sustainable and eco-friendly printing practices.

Technological Advancements

There are different types of water-based inks, such as high solids, medium solids, and low solids.

We also want to share an advanced method for achieving superior quality outcomes: discharge ink.

Unlike typical water-based inks, discharge ink contains an activator that removes the original dye from the fabric, reverting it to its natural, undyed color.

This process allows for the addition of pigments to the ink, effectively re-dyeing the fabric in the desired color. The necessity of this technique stems from the challenge of printing on pre-dyed fabrics.

This innovative approach significantly enhances the quality and vibrancy of the final product.

Consumer Industry Shifts

The fashion industry is advancing towards a greener future.

According to Genomatica’s research, 55% of consumers are interested in purchasing sustainable clothing (and we expect this percentage to keep growing), but 48% of them don’t know where to find it.

You can lead the pack by promoting the eco-friendly attributes and superior quality of water-based inks to differentiate yourself in a crowded marketplace. This approach strengthens your brand’s market presence.

Regulatory Changes

As environmental regulations become more stringent, businesses are under increasing pressure to adopt sustainable practices. 

By transitioning to water-based screen printing, you can align yourself with evolving environmental standards, making your apparel more compliant and competitive.

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Things to Know Before Using Water-Based Ink

Water-based ink isn’t a walk in the park. There is a vast difference between other inks and water-based inks. 

If you’re contemplating a shift from plastisol to water-based inks, it’s crucial to understand the challenges that lie ahead.

Here are a few things to know about water-based ink:

Longer Drying Time

A key disadvantage of water-based inks lies in their extended drying times when compared to plastisol inks. This extended drying period can decelerate the production workflow, potentially necessitating the use of supplementary equipment, such as forced-air dryers, to expedite the drying process.

Plastisol Wins in Vibrancy

Water-based inks tend to absorb into the fabric—resulting in slightly less vibrant colors compared to plastisol ink.

While not dull, the prints may not achieve the same brightness and may show some fabric texture through the design. Keep this in mind when you’re choosing the right ink for your project.

The Base Garment Color Matters

For optimal results with water-based screen printing, light-colored shirts are recommended because the ink’s visibility is more vibrant on a lighter base. 

However, if you prefer darker shirts, you can use discharge screen printing to achieve good results. While discharge printing offers a vintage look and high-quality finish, it tends to be more costly and requires specific inks. Read more pros and cons of discharge screen printing.

Learning Curve

Transitioning from plastisol to water-based inks requires adjustments in printing processes and techniques due to the distinct behavior between the inks. That’s why we don’t recommend tackling it solo. Leverage the expertise of a trusted manufacturing partner to help you produce your garments.

Higher Costs for the Best Technology

The downside to discharge screen printing is that it can be a bit more expensive, and it requires specific discharge ink. The cost is due to the special ingredients necessary for the discharge process, as well as the more complex techniques and equipment needed to apply these inks effectively.

However, by opting for the best technology available, you are positioning your brand at the forefront of sustainability and excellence.

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Take Water-Based Screen Printing to the Next Level With Scrappy Apparel

At Scrappy Apparel, we understand the unique challenges that come with transitioning to water-based inks. That’s why we offer comprehensive support to our partners, ensuring a smooth and successful transition.

World-Class Screen Printing Quality

Our water-based screen printing inks are non-toxic, free from lead and heavy metals, and devoid of ozone-depleting chemicals (such as CFCs and HCFCs) or volatile solvents.

We’re Experts in Water-Based Screen Printing

Our team has printed hundreds of thousands of t-shirts using water-based ink.

Water-based screen printing demands a unique approach compared to conventional printing techniques, which is why we highly recommend you work with a trusted expert (like us!)

The entire process requires careful adjustments and modifications. Whether you choose our services or go with another provider, ensure they have a deep understanding of water-based screen printing.

We Offer End-to-End Apparel Supply Chain Management

Take control of your logistics with our comprehensive 3PL MGMT program and end-to-end supply chain management solutions.

By partnering with us, you gain access to expert coordination from production to delivery, ensuring efficiency and reducing your operational hassles.

Our solutions are designed to handle every aspect of your supply chain, from sourcing raw materials and manufacturing to warehousing, distribution, and customer fulfillment. 

We give you 100% transparency every step of the way, so you’ll always rest easy knowing what’s going on with your brand.

Don’t let supply chain complexities slow down your growth. Allow us to optimize your operations, cut costs, and improve your overall garment quality. 

That way, you can focus more on your core business and less on the logistics.

Choose Scrappy Apparel to Put Your Brand at the Forefront of Innovation and Excellence!

If you’re operating a franchise, maintaining a cohesive image is key to ensuring each location represents your brand’s excellence and spirit.

That’s why uniforms are so crucial—they serve as a visual endorsement of your brand’s values and professionalism.

However, high-volume apparel production for franchises comes with a unique set of challenges, like:

• Consistency Across Locations: How can you ensure that uniforms at one franchise look exactly the same as those 500 miles away?
• Scalability Challenges: How do you manage sudden increases in order demands, especially in rapid growth phases or during promotional seasons?
• Cost Control: How can you keep costs down without affecting the quality of the uniforms?
• Supply Chain Management: What are the best practices for coordinating with manufacturers and suppliers to ensure timely deliveries?

At first, these challenges can seem significant… but what if we told you there’s an all-in-one solution that can help you address all of these challenges head-on?

With Scrappy Apparel, you can overcome the operational hurdles of high-volume apparel production and focus more on what matters—growing your franchise and enhancing your brand’s presence.

Sounds like a recipe for success? Let’s explore these concepts further.

Leverage Scrappy Apparel’s High-Volume Apparel Production Capabilities!

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We Know What You’re Thinking—Why Not Manufacture Uniforms In-House?

Some organizations have in-house apparel divisions that can manufacture uniforms as needed. Of course, there are benefits that come with this approach, but there are also many potential risks to consider.

Here’s an overview of each:

Benefits

• Complete Control Over Production – Managing the entire production process internally allows for greater control over every aspect of uniform manufacturing, from material selection to final output.
• Flexibility and Customization – In-house production provides the ability to quickly adapt designs and make customizations based on specific needs without the constraints or delays that might come with external suppliers.
• Faster Response Time – Having the manufacturing process under the same roof can significantly reduce the lead time from design to distribution, enabling faster responses to changing demands or emergency needs within your organization.
• Improved Inventory Management – Direct oversight of production helps in better inventory management, allowing organizations to maintain optimal stock levels and reduce excess inventory waste.

Potential Risks

• Variable Demand – You’ll often see shifts in manufacturing due to economic factors, seasonal changes, and other variances. Forecasting and adapting to these fluctuations is a significant challenge that impacts inventory management and production strategies.
• Global Supply Chain Disruptions – Global events like natural disasters, political unrest, or health crises can significantly disrupt the supply chain, causing delays in getting raw materials, slowing production, and creating logistical challenges. If you don’t know what you’re doing, this can be disastrous.
• Variable Cost of Raw Materials – Variations in the cost of raw materials, including cotton, polyester, and various other textiles, significantly affect the production cost. If you’re manufacturing thousands of units, these variations can wreak havoc on your budget.
• Ensuring Quality and Maintaining Uniformity – Maintaining quality in large batches of workwear is challenging. The suppliers you work with must follow strict quality controls to meet industry standards (and you must enforce those standards).
• Talent Shortages – The workwear industry depends on skilled labor for tasks like design, pattern-making, cutting, and sewing. Shortages in these areas can raise labor costs and cause production delays. Again, this is a nightmare waiting to happen.

Here’s a startling stat: According to research by Deloitte, only 26% of respondents could predict risks within their supplier base. As you can see, the risks could far outweigh the benefits for your organization—but it’s up to you to decide.

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Let’s Say You’ve Decided to Work with a Third-Party Manufacturer. How Can You Cut Costs While Maintaining Quality?

Uniforms are an investment in your brand’s future. They show your dedication to excellence. 

While we never recommend cutting costs at the expense of quality, we understand that budget is important to every franchise. Here are some factors to consider if you’re looking for cost-effective uniform manufacturing solutions:

Leverage Economies of Scale

The first tip is a common one, but we can’t ignore it. In most cases, bulk purchases drive down the unit cost of each item, allowing you to enjoy better margins or pass savings onto franchisees. This approach also increases your negotiation power with your partner.

Build Strong Relationships With Your Manufacturer

Building this relationship can result in improved pricing, preferred production timetables, and access to superior materials.

Maintain transparency about your needs and collaboratively seek economical solutions that maintain quality standards. 

P.S. Choosing Scrappy Apparel’s 3PL MGMT program is the best way to minimize supply chain risks. (More on this later!)

Implement Just-in-Time (JIT) Inventory Management

Implementing a Just-In-Time (JIT) inventory system can significantly cut costs associated with storing vast amounts of inventory, as it involves ordering goods only when necessary.

While this method demands accurate planning and forecasting, it can greatly reduce inventory-carrying costs and minimize waste. One example of success is Harley-Davidson USA, which reduced its inventory by 75% with JIT.

Additionally, you will need a flexible manufacturing partner if you want to succeed with this approach. Make sure you choose a manufacturer that can produce the garments on time (never, ever late!) and keep their commitments to your brand.

Quality Control Systems

Implement strict quality control measures to ensure every uniform shines to your brand’s high standards. You’ll want to have your own internal processes, but you should make sure your manufacturing partner is on the same page about quality control. 

You can eliminate back-and-forth (and save money) by choosing a manufacturer that does multiple quality control checks on their end.

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How to Ensure On-Time Delivery To Multiple Locations

On-time delivery is the backbone of trust and reliability in any franchise operation.

When franchisees receive their uniforms on time, they’re equipped to present a unified, professional image from day one. It also directly impacts customers’ perceptions and the overall brand experience.

Here’s how you can make sure your team has their uniforms when they need them:

Meticulous Planning

Let’s say you’re hosting a company-wide event that calls for special uniforms, and you need to coordinate deliveries to over 50 franchise locations across the country by a specific date.

You need to start your planning months in advance, mapping out each step of the production, packaging, and distribution phases. Work closely with your manufacturing and logistics team to:

• Establish a clear timeline
• Calculate inventory levels to ensure enough materials are on hand
• Evaluate production capacities
• Use real-time tracking systems
• Optimize delivery routes
• Prepare contingency plans for last-minute issues
• Consider any other relevant details

By the time the launch date approaches, all items need to be ready for dispatch. Your partner should be briefed in detail, with routes optimized for efficiency and contingency plans in place.

Maintain Open and Clear Communication

Never underestimate the power of clear, open, and honest communication.

Communication is the foundation to build and maintain trust with your manufacturer. Regularly update your partner about your expectations, needs, challenges, or changes in the partnership. Also, engage in direct dialogue and provide feedback to help your partner be successful.

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Scrappy Apparel is Your All-in-One Franchise Uniform Solution

We have the three things you need to facilitate successful uniform deliveries across all franchise locations:

• A manufacturing powerhouse with the flexibility to scale up or down as demands change
• Streamlined fulfillment solutions that ensure on-time delivery to multiple locations throughout the U.S.
• Modern inventory management systems that can keep track of stock levels and make sure your uniforms are ready to go when you need them

Instead of juggling multiple vendors, you can trust Scrappy Apparel to manage the entire supply chain for you. Enjoy more of your valuable time back!

Expert Manufacturing Processes

We take care of all the tedious tasks associated with manufacturing, like sourcing materials and choosing the right printing processes.

We collaborate with reputable suppliers globally to guarantee superior uniform production quality, competitive pricing, and prompt delivery.

We’ll work with you to ensure your uniforms turn out just as you imagined they would.

High-Volume Corporate Fulfillment Solutions

We offer corporate fulfillment solutions designed for large organizations and franchises that need to store thousands of garments at a time until they’re ready for shipment.

Here are some of the ways we’re currently helping our franchise customers:

• Warehousing – We provide ample storage space to accommodate the high-volume uniform inventory. Our secure facilities ensure that your merchandise is stored safely and efficiently until needed.
• Order Fulfillment – When new employees join your workforce or existing employees require uniform replacements, Scrappy Apparel springs into action. We swiftly process orders, picking and packing items with precision to ensure accurate fulfillment.
• Lightning-Fast Shipping to Multiple Locations – With our nationwide logistics network, we excel at shipping orders to individual locations across the USA. Whether it’s sending uniforms to multiple branches, offices, or stores, we coordinate logistics seamlessly to ensure timely delivery.

Enjoy Precise, Punctual Manufacturing and Fulfillment Services Across the U.S. with Scrappy Apparel!