Manual screen reclaiming is still a key part of many screen printing shops, especially those that value flexibility and control over speed. It’s a step-by-step process that, when done correctly, leaves screens clean and ready for a fresh coat.
The manual process typically takes 5–10 minutes per screen, depending on emulsion type, mesh count, and ink complexity. This timeline can extend significantly when dealing with stubborn stains or specialty emulsions.
Manual reclaiming isn't outdated — it's the right choice for specific operational profiles.
Manual reclaiming remains the practical choice for shops processing fewer than 20 screens per day. This volume threshold allows for manageable turnaround times without dedicating excessive labor to reclaim tasks. Custom shops handling one-off jobs or varied screen types benefit from the hands-on control that manual methods provide.
The financial barrier to entry for manual reclaiming is minimal. A complete manual setup runs approximately $500–$2,000. This allows newer shops to allocate capital toward other production needs while establishing their reclaiming workflow. The gradual scaling capability means you can add tools and refine processes as volume increases without major equipment commitments.
Manual reclaiming gives operators direct tactile feedback and visual inspection throughout the process. This matters when handling delicate mesh counts, specialty emulsions, or screens with complex stencil details. Operators can adjust pressure, dwell time, and chemical application based on real-time assessment.
Automated reclaiming technology has evolved significantly, moving from basic spray cabinets to sophisticated closed-loop systems that integrate chemical dosing, high-pressure cleaning, filtration, and recirculation.
Modern automated reclaimers follow a standardized sequence: load screen → automated chemical application → high-pressure rinse → drying (in some models).
Bluewater systems incorporate precision dosing that applies exact amounts of Easiway's emulsion removers and haze removers, eliminating the guesswork and waste inherent in manual application. Integrated filtration systems capture emulsion solids and enable chemical recirculation, dramatically reducing both water and chemistry consumption.
The case for automation extends beyond speed — it fundamentally changes reclaim quality, consistency, and operational efficiency.
Automated systems eliminate operator variability. Every screen receives identical chemical exposure, pressure, and rinse timing. This uniformity improves stencil integrity on subsequent jobs and reduces mesh damage from over-aggressive manual scrubbing or inconsistent chemical contact. For shops running tight registration work or fine halftones, this consistency directly translates to fewer remakes and better on-press results.
Bluewater's automated systems clean screens in approximately two minutes per screen. At medium to high volumes, this time savings compounds rapidly. Switching to automated reclaiming allows labor to be more focused on production, quality control, or other value-added tasks instead of standing at a washout booth.
Manual reclaiming typically suffers from over-application — operators apply more chemistry than necessary to ensure complete emulsion removal. Automated systems using Easiway's optimized dosing protocols apply precisely the amount needed, no more.
Automated systems show up every day. Unlike manual processes that depend on operator technique, experience, and consistency, automated reclaimers deliver predictable results shift after shift. Training new staff becomes dramatically simpler — load screen, press start — compared to teaching proper scrubbing technique, chemical application timing, and troubleshooting haze issues.
Volume thresholds determine which reclaiming approach delivers the best balance of throughput, cost, and operational fit.
At this volume, manual reclaiming remains cost-effective and operationally sufficient. The $60,000+ investment in full automation is difficult to justify unless labor costs are exceptionally high or growth is imminent. Manual methods provide adequate throughput while preserving capital for other business needs.
This range represents the inflection point where automation begins delivering tangible ROI. Shops in this bracket should evaluate Bluewater's HP-1 machine, which bridge manual and fully automated workflows. These semi-automated systems offer automated chemical application paired with manual or power-assisted rinsing — capturing significant time savings without requiring full inline infrastructure.
Automation becomes essential at this volume. Manual reclaiming simply can't keep pace without dedicating multiple full-time staff to the reclaim area — an inefficient allocation of skilled labor. Bluewater's Reclaim Series Machines provide the throughput, consistency, and scalability that high-volume operations demand.
These full inline systems integrate seamlessly with automated exposure units, dryers, and coating equipment, creating a continuous workflow from reclaim through re-coating. For shops running multiple shifts or pursuing contract manufacturing, this infrastructure enables predictable turnaround times and consistent quality at scale.
Volume provides the starting point, but your reclaiming decision should also account for budget constraints, quality requirements, growth plans, and facility layout.
Manual setup: $500–$2,000 (washout booth, pressure washer, filtration, chemicals)
Semi-automated systems: $20,000–$40,000 (Bluewater HP-1 or equivalent)
Automated inline systems: $60,000+ (Bluewater RS/RL Series)
ROI calculations should account for direct labor savings, reduced chemical costs through optimized dosing, decreased mesh replacement from gentler handling, and improved throughput, enabling revenue growth. Most shops realize ROI within 12–24 months on automated systems, with semi-automated setups often paying for themselves even faster.
Shops running high-end work — fine halftones, process color, tight registration — especially benefit from automation's consistency. Variability in reclaiming directly affects stencil quality, which impacts on-press registration and color matching. Automated systems also reduce mesh damage through consistent, controlled pressure application and elimination of aggressive manual scrubbing.
Equipment purchases should anticipate growth, not just address current needs. Bluewater's modular systems allow shops to start with semi-automated solutions and expand to full inline setups as volume increases. This scalability matters — you're not starting over with new equipment when you outgrow your initial investment. The systems easily integrate with exposure units, coating equipment, and dryers, enabling comprehensive workflow automation as your operation matures.
Manual reclaiming requires minimal space — a washout booth and sink occupy 6–10 square feet. Semi-automated systems need 6–10 linear feet, while full inline conveyors can require 15–20 feet. Assess your reclaim area layout before committing to automated equipment. Bluewater provides layout consultation to optimize workflow and minimize production disruption during installation.
Transitioning to automated reclaiming is less disruptive than many shops anticipate, though it's not without challenges. Installation and setup typically require a few days, with full transition — including staff training and workflow optimization — completing within one week. Bluewater provides comprehensive support throughout the transition: on-site installation, technician setup, staff training, and post-installation troubleshooting.
The right reclaiming method depends on where your shop is today and where you're headed tomorrow. Bluewater's equipment, paired with Easiway's screen reclaiming chemistry, delivers optimized performance at every volume level — from semi-automated systems for growing shops to full inline solutions for high-volume operations.
Ready to explore automated reclaiming for your shop? Contact Bluewater for an equipment quote today.