A well-organized chemical storage area isn't just about aesthetics — it's about safety, efficiency, and preventing costly mistakes. Here's how to set up a system that works.
This is critical for safety. One of the most common and dangerous mistakes we see in screen printing shops is storing incompatible chemicals together. Flammable solvents must be stored away from oxidizers and acids. When incompatible chemicals sit too close together, you're risking dangerous reactions that could lead to fires, toxic fumes, or worse. Take the time to look at Safety Data Sheets to determine which products shouldn't be neighbors and create separate zones accordingly.
When new stock arrives, move older products to the front and place new containers behind them. This simple practice prevents chemicals from sitting unused until they've expired, reducing waste and ensuring you're always working with fresh, effective products.
Label your shelves and storage zones clearly. Every chemical should be identifiable at a glance, and every storage area should be marked with what belongs there. Lack of proper labeling and documentation creates confusion and serious safety risks. When chemicals aren't labeled or when documentation is missing, mistakes happen — and in a shop environment, those mistakes can be hazardous.
Where and how you store chemicals directly impacts their effectiveness and your shop's safety. Let's break down what you need to know.
Store chemicals in cool, dry areas away from direct sunlight and heat sources. Temperature fluctuations can cause chemicals to break down, lose effectiveness, or become volatile. If you're storing chemicals in a garage or warehouse that isn't climate-controlled, you're inviting problems. Improper temperature — especially storing products in areas with fluctuating heat — is one of the leading causes of chemical degradation we see in shops.
Proper airflow prevents vapor buildup from volatile compounds, which is both a safety issue and a quality concern. Toxic exposure from volatile compounds stored without adequate ventilation is one of the biggest safety risks in screen printing shops. Make sure your storage area has adequate ventilation — mechanical ventilation systems are ideal, but at a minimum, ensure air can circulate freely. Air filtration also helps reduce airborne contaminants that could affect product performance or employee health.
Chemical spills due to improper container sealing or stacking are all too common. Use spill trays or containment bunds under liquid chemicals, especially larger containers. This prevents a small accident from becoming a major cleanup operation or, worse, a hazardous situation.
Light-sensitive chemicals need special attention. Store these products in opaque containers away from direct light sources. UV exposure can break down active ingredients, rendering your chemicals less effective or completely useless.
Always reseal containers immediately after use — this single habit will extend the life of your chemicals significantly. If you're transferring products to smaller containers for daily use, make sure those containers are appropriate for the chemical and properly sealed. Using non-original containers increases the risk of mislabeling and degradation, so if you must transfer, label clearly and use appropriate containers.
Keep flammables in approved cabinets, away from ignition sources, and never store them near heat-generating equipment. The few extra steps to store flammables correctly could prevent a catastrophic loss.
If you can't track it, you can't manage it. Good documentation practices are the backbone of effective chemical inventory management — and one of the most common mistakes is having no tracking system at all, which leads to loss, waste, and compliance issues.
Small shops often start with manual tracking using spreadsheets, and that's fine when you're getting started. But as you grow, digital inventory management software becomes worth the investment. The time saved and errors prevented pay for the system quickly.
These technologies enable real-time updates and eliminate manual data entry errors. When someone grabs a bottle of product, a quick scan updates your inventory instantly. Barcode and RFID tracking provide real-time updates that keep everyone on the same page, from the production floor to purchasing.
Many inventory systems now offer mobile apps that allow your team to update inventory, photograph low-stock situations for visual reference, check usage history, and even pull up Safety Data Sheets on the fly. Photo documentation for visual inventory is particularly useful during physical counts or when training new employees on where products are stored.
Don't cut corners on documentation. For every product in your inventory, maintain records of:
This might seem like a lot, but when you're troubleshooting a quality issue, responding to a safety inquiry, or dealing with a regulatory inspection, you'll be grateful for comprehensive documentation.
Every chemical in your shop must have an accessible SDS. Lack of proper SDS management is a compliance violation waiting to happen. Keep both physical copies in a clearly marked binder and digital copies in a shared system where every employee can access them. When regulations require immediate access to this information, scrambling to find the right document isn't an option.
Logging how much of each chemical you use over time reveals patterns you can use for better forecasting. Track which jobs use which products, how consumption varies by project type, and which chemicals consistently run low. This data becomes invaluable for smart purchasing decisions and helps you avoid both overstocking and understocking.
Automated alerts prevent the dreaded "we're out" scenario during a rush job. Configure your system to notify you when products hit predetermined reorder points. Even a simple spreadsheet can use formulas to flag items that need attention, but dedicated software makes this effortless and ensures nothing slips through the cracks.
Set up alerts well before chemicals expire so you can plan to use them up rather than dispose of them. Some systems can send reminders at 30, 60, and 90 days before expiration, giving you time to adjust usage or avoid reordering products you already have in stock.
Stocking too many chemicals ties up capital and risks expiration. Stocking too little causes delays and missed deadlines. Finding the sweet spot requires understanding your actual usage patterns.
Look at your historical data to see how much of each chemical you typically use per week or month. This is where your usage logs pay off. If you use a gallon of emulsion remover every two weeks, you can plan accordingly. Consider your supplier's lead time — if Easiway delivers in five days, you know you need to reorder when you're down to about half a gallon to avoid running out.
Some chemicals have short shelf lives, while others stay stable for years. Consider both the manufacturer's stated shelf life and your supplier's reliability when setting inventory levels. If your supplier is consistently on time, you can maintain leaner inventory. If deliveries are unpredictable, build in more buffer stock for critical items.
Not every week is the same. Some jobs use more ink, others require more cleaning supplies. Build some buffer into your calculations to account for unexpected demand spikes or unusually large jobs.
Many screen printing shops experience busy and slow seasons. If you do a lot of apparel printing for events, your summer months might be slammed while winter is quiet. Adjust your inventory levels accordingly — don't stock like it's peak season year-round. Look at your usage data from previous years to identify these patterns and plan purchases around them.
This formula helps you determine the most cost-effective order size by balancing ordering costs against holding costs. While it sounds complex, there are free EOQ calculators online. Input your annual usage, cost per order (shipping, processing time, etc.), and holding cost per unit (storage, insurance, potential spoilage), and it tells you the optimal order quantity for cost efficiency.
Even if bulk buying saves money, it doesn't make sense if you don't have proper storage space. Chemicals stored in inappropriate conditions because you overbought are worse than paying a bit more for smaller, more frequent orders. Be realistic about your physical space and storage capabilities.
Even the best inventory system fails if your team doesn't know how to use it properly. Employee training on chemical handling and storage isn't optional — it's essential for safety, compliance, and operational efficiency.
Your employees need to understand how to read and interpret Safety Data Sheets, recognize hazard symbols and classifications, understand the risks associated with each chemical they handle, and know where to find SDS documents quickly. This isn't optional — it's required by OSHA, and for good reason.
Make sure everyone knows what personal protective equipment is required for each product, how to properly don and remove PPE, when PPE needs to be replaced, and what to do if PPE is damaged or unavailable. Gloves, safety glasses, and respirators only protect people when used correctly and consistently.
What happens if someone spills a gallon of screen opener? Every employee should know: how to contain a spill safely, where the spill kit is located, who to notify, when to evacuate, and how to properly dispose of contaminated materials. Practice spill response procedures so they're second nature in an emergency.
Your team needs to understand why chemicals must be stored in specific locations, how to identify incompatible products, why sealing containers immediately matters, proper lifting and handling techniques for heavy containers, and the importance of FIFO rotation. When they understand the "why" behind the rules, they're more likely to follow them consistently.
If you're using barcode scanning or inventory management software, ensure everyone knows how to update the system when using products, check current stock levels, flag low-stock situations or quality issues, and generate reports when needed.
If you're just getting serious about inventory management, begin with these foundational practices:
At minimum, track what you have, how much, where it is, and when it expires. A simple spreadsheet works fine initially.
Every container should be clearly labeled, and every product should have an accessible Safety Data Sheet. This is both a legal requirement and a practical necessity.
Don't scatter chemicals throughout your shop. Create specific storage zones with proper ventilation and environmental controls.
Before anyone touches a chemical, they should understand the hazards and know how to protect themselves.
You don't need fancy software to start — you just need consistent tracking. As your needs grow, your system can grow with you.
The shops that excel at chemical inventory management establish clear systems and stick to them. They prevent problems, save money by using products before expiration, and keep production running smoothly. Most importantly, they maintain safe working environments where employees can focus on creating great prints.
Ready to stock your shop with reliable, safe chemicals? Browse our complete line of screen printing products!