What type of printing do you do?
Castle does dye sublimation transfer printing onto fabric or direct printing onto non-wovens, using rotary screens.

How wide can you print?
Up to 130” wide.

How many colors can Castle print on one design?
Up to 16 colors.

What is the cost of engraving rotary screens?
This depends on the design itself. We have different screen circumferences to accommodate a wide variety of repeat sizes. A quote can be given by e-mail once we know the repeat size or view the design.

What is the cost of printing?
This will depend on how much is being printed. The price drops the more yardage is ordered. A quote and/or price list be sent once we have the design information.

What is the cost of transferring the paper onto the fabric for sublimation projects?
See above.

I am confused by the process of dye sublimation using rotary screens. How does it work?
Once a design is approved for printing, it is set up to be engraved onto rotary screens/cylinders made of nickel coated with a lacquer. Each color in the design gets its own screen. A special laser burns the part of the design that represents the specific color into each screen. If the design has 5 colors, there will be 5 screens. The screens are then loaded into the print machine. Meanwhile, dyes have been matched and mixed, and are ready to go into each specific slot on the print machine. The design is then printed onto sublimation paper, or directly onto non-wovens. Upon completion, the finished roll is inspected and shipped. If it is sublimation paper, it is then run through a heat calendar(called “transferring”)which sublimates the ink from the paper permanently into the fabric. Then you have your finished product, which requires no finishing such as steaming, washing etc.

What are your run length minimums?
Our minimum is 2000 yards (between 500 and 2000 yards, surcharges will apply).

Can you print on light weight non-wovens?
Yes. For more information on our non-woven printing options, click here.

Does Castle Industries take safeguards to protect the environment?
Yes, this has been our way of doing things since our doors opened. For complete information on our environmentally friendly printing process, click here.