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Smiling multicultural printing and graphic industry workshop female technologists standing at printing workshop with silk screen printed t-shirt and doing quality control.

Plastisol ink vs. Water based ink: what’s different?

 

Screen printing relies heavily on the choice of ink, and the debate between water-based and plastisol inks continues to shape industry practices. So, what’s the deal with plastisol versus water-based ink? Ink is one of the most essential components in screen printing. For a long time, plastisol inks were the dominant choice, as water-based inks posed significant challenges in usability. Plastisol inks served printers well, enabling them to create vibrant and detailed designs. However, being oil-based, plastisol inks require a variety of chemicals for cleanup and aren’t considered sustainable or eco-friendly.


Rethinking ink: the rise of water-based alternatives in screen printing

In recent years, advancements have been made in water-based inks, offering viable alternatives for printers. For instance, Ryonet’s Green Galaxy HSA Water-Based Inks are environmentally friendly, stay wet in the screen longer, require little to no chemicals for cleanup, and provide a soft, high-quality finish on garments. This evolution has reopened the conversation about which type of ink is better for specific applications and priorities.

Choosing between water-based and plastisol inks for screen printing is a nuanced decision that depends on multiple factors, including the desired print quality, fabric type, and environmental considerations. Both types of inks have distinct advantages and challenges, and understanding their characteristics can help you make an informed choice for your specific needs.

 

Water-based inks: the softer, eco-friendly choice with practical trade-offs

Water-based inks, with their soft, premium feel and eco-friendly properties, are gaining popularity. However, their practical trade-offs make them a nuanced choice for screen printers. Here are their pros and cons in full details:
Pros:

  • Soft, high-end feel: water-based inks penetrate the fabric, resulting in a print that feels softer and lighter. This makes them ideal for garments that require a premium, professional finish that customers appreciate.

  • Eco-friendly cleaning: cleaning up after using water-based inks doesn’t require harsh chemicals, which is a key eco-friendly advantage and contributes to safer workplace practices for printers.

  • Versatility: certain water-based inks can be used for printing on both fabrics and paper, making them highly adaptable to a variety of creative projects, including mixed-media applications.


Cons:

  • Screen drying issues: these inks tend to dry in the screen more quickly, leading to clogging if not used at a consistent pace. Printers need to work efficiently and may require specialized additives to extend drying times.

  • Emulsion breakdown: without the right emulsion, the screens can degrade mid-run, disrupting production and increasing downtime.

  • Transparency: water-based inks are often less opaque, necessitating an underbase for printing on medium to dark garments, which can add complexity to the process.

  • Environmental trade-offs: while perceived as more eco-friendly, water-based inks can require significant water usage for cleaning, which is a concern in arid regions or areas facing water scarcity.
A person holds a plain white T-shirt in a workshop equipped with a multi-needle embroidery machine, spools of colorful thread, and screen printing inks.

Bold colors, tough curing: navigating plastisol inks for screen printing

Plastisol inks deliver bright, eye-catching prints, but proper curing and chemical cleanup can be challenging. We’ll explore the pros, cons, and key tips for making the most of these vivid inks without getting stuck in the details.


Pros:

  • Vibrant colors: plastisol inks excel in producing bold, bright, and opaque colors, especially on darker garments. This makes them perfect for eye-catching designs and logos.

  • Production efficiency: unlike water-based inks, plastisol doesn’t dry in the screen, reducing interruptions during printing and allowing for smoother workflows.

  • Durability: these inks are less prone to causing emulsion breakdown and are highly reliable for long production runs, ensuring consistent results across large orders.


Cons:

  • Chemical dependency: cleaning plastisol inks requires chemicals, which can be less environmentally friendly and may require proper disposal methods to avoid environmental impact.

  • Thicker prints: prints using plastisol are heavier and less breathable, which some customers may find uncomfortable for everyday wear.

  • Exacting curing requirements: over-curing can lead to cracking, while under-curing leaves the print tacky, so achieving the right curing temperature is crucial for long-lasting results.
A close-up of a person’s hand using a metal squeegee to spread thick red ink across a screen printing frame, with jars of various colored inks visible in the background.

Facing off: water-based vs. plastisol inks across 7 key factors

When it comes to screen printing, choosing between water-based and plastisol inks can make all the difference. Below is a head-to-head comparison of these two popular options across seven crucial factors: from color vibrancy to environmental impact, determine which ink best fits your needs.


1. Feel and weight

Water-based inks absorb into the fabric, resulting in a lightweight, softer feel that blends seamlessly with the garment. In contrast, plastisol creates a heavier print since it sits on the fabric's surface, which can feel more rigid. For dark garments, water-based inks often rely on discharge techniques to achieve a soft hand. This method removes the fabric’s dye but is limited to 100% cotton garments, making fabric selection a critical consideration.


2. Color vibrancy

Plastisol inks are the go-to choice for vibrant, saturated colors that pop, particularly on dark fabrics. They create a solid, opaque layer that ensures consistent color reproduction. Water-based inks, while excellent for achieving a muted or vintage look, struggle to match plastisol’s brightness and opacity. For designs requiring bold, standout visuals, plastisol is the better choice.


3. Color accuracy

Plastisol inks offer superior color accuracy, making them ideal for branding or designs requiring precise Pantone matches. This is particularly important for maintaining consistency across large-scale production runs. Water-based inks, being more transparent, can result in slight color shifts depending on fabric type and press conditions, making them less suitable for projects requiring exact color matching.


4. Durability

Both ink types are highly durable when properly cured. Water-based prints last as long as the garment itself, as the ink integrates into the fabric. Plastisol, forming a layer on top of the fabric, also offers excellent longevity if curing is correctly managed. Proper care of the garment, such as washing with mild detergents and avoiding high heat, can extend the life of the print for both ink types.


5. Breathability

Water-based inks allow for better breathability as they don’t block fabric fibers, making them ideal for athletic wear or lightweight garments. Plastisol prints, especially with large, solid designs, can create a “sweat patch” effect by sealing the fabric surface. This can be uncomfortable for activewear but may not be a concern for designs intended for casual or occasional use.


6. Versatility

Plastisol is more versatile across fabric types, working well with blends, synthetics, and specialty fabrics. This flexibility makes it a favorite for diverse product lines. Water-based inks perform best on 100% cotton and can struggle with synthetic materials, making them less flexible for varied applications. Printers need to carefully assess fabric composition before selecting water-based inks.


7. Environmental impact

While water-based inks are marketed as eco-friendlier, they have drawbacks. They require significant water for cleaning and may introduce pigments into wastewater systems that are difficult to filter. Plastisol inks, though less “green,” are evolving to include phthalate-free options to reduce toxicity and comply with industry regulations. Choosing between the two often involves balancing production efficiency with environmental responsibility.

 

Plastisol ink, water based inks… A comparison of both in a youtube video

It’s time to stop arguing about plastisol versus water based inks! There are options for both kinds of printing, with benefits to both. Choose what’s best for you, and tell us what you prefer and why in the comments below! Check out this video to see Josh talk a little bit more about it from the youtube channel Ryonet:



Choosing the right ink

The choice between water-based and plastisol inks depends on the specific needs of your project:

  • Water-based ink: best for light-colored garments, intricate designs, and a soft, high-end feel that appeals to premium markets.

  • Plastisol ink: ideal for dark garments, bold designs, and high-volume production runs where consistency and vibrancy are paramount.


Ultimately, there’s no definitive “better” ink. Each has strengths suited to particular circumstances. By understanding these differences, printers can make informed decisions that align with their creative and operational goals, ensuring the best outcomes for both the printer and the customer.

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