How to Avoid Ghosting in Sublimation Transfers

The issue of ghosting is by far the most irritating in sublimation printing especially when customizing the sportswear, which includes jerseys, leggings and team sets. Ghosting will ruin the designs you have. There would be the light traces, or duplicate image that would ruin the appearance and professionalism of the garment.

What is Ghosting in Sublimation of sportswear?

Ghosting in sublimation is faint shadows, two images and vague outlines of the print that appears on the garment during the press. They are unwanted prints which are usually created about logos, texts or any other design, therefore making the product unprofessional. Ghosting can be slight and observable, especially on dark or light-colored material.

The secret of ghosting prevention is to learn to get the alignment and pressing procedure right so that the ink transfers onto the fabric, and it does not shift during the sublimation process.

Why Ghosting Happens More on Sportswear Fabrics

Sport fabrics, especially those that are oriented towards performance fabrics and elasticity, are specifically difficult to sublimate. The most probable garment of sublimation sportswear that is prone to be utilized is the polyester, hence most likely to move or even bend when compression occurs between the heat effect and thus, results in ghosting.

However special finishes (ex: moisture-wicking, UV-protection), may be incorporated into sportswear, and the latter may lead to the misplacement of the design, or the ink to start adhesion. Clothes with elastic properties left extremely high chances of ghosting since the clothes are elastic when stretched.

The Most Common Causes of Ghosting in Sportswear Sublimation

Fabric Movement/ Transfer Sheet

Cause:

It may be caused when the fabric or transfer sheet is moved I even an inch during the pressing process, and consequently, ghosting can occur. The slightest alteration will lead to dark edges or smoked prints.

Fix:

Ensure that transfer sheet and fabric are properly laid and attached and then pressed.

Over- or Under-Repeated Heat/Time/Pressure of Activewear Fabrics

Cause:

Certainly, the sportswear fabrics possess certain amount of heat, time and pressure requirements in the sublimation process. Too much heat or pressure can in turn result in stretching or shifting of the fabric and too little will result in a lack of saturation of colors and ghosting.

Fix:

Choose heat press settings based on the type of fabric and so does a test on fabric swatches to ensure that the bonding and colorful prints are flawless.

Sweat and Moisture-Holding Fibers

Cause:

Having a damp fabric (and therefore the humidity or sweat that was not washed out) could interfere with the process of sublimation and cause ghosting. Even the materials that absorb moisture like the moisture-wicking polyester are not even during the pressing process.

Fix:

Prior to the sublimation process, ensure that the fabric is totally dry and in your production facility, use should be made of dehumidifiers or moisture containment.

Ink Oversaturation from High-Density Prints

Cause:

The amount of ink used in a print design (such as deep colors or gradient color) may be excessive to such an extent that the fabric absorbs more ink, thereby ghosting where the more ink diffuses out of the intended use.

Fix:

Adjust the appropriate density of the design and change the level of ink. Check on excess and test the designs where possible.

Non-uniform Pressure on Cut Panels

Cause:

The sublimation can be ghosted in conditions of the unequal load of the meshes on the fabric panels, specifically, with clothes that have several parts (e.g., a jersey with mesh panels or side seams).

Fix:

They must be pressed by ensuring that even pressure is applied on all the fabric panels and also not excessively thick or thin.

Remaining Oils, Finishing Agents or Pre-Coats

Cause:

The sportswear may contain oils, finishing agents or pre-coats that were left on in the manufacturing process used. These can cause the sublimation ink to fail to be bonded fully to the fibers, hence ghosting.

Fix:

Wash cloth in before sublimating in a washing machine or add any existing dirt that will ruin the process of transferring the ink.

Swivelling in Batch Stock
Cause:

Sometimes, even the slightest variation in the batches of fabric such as dye lot, fabric weight or fiber content can cause the uneven uptake of ink.

Fix:

Batches of fabric should be of the same lot of fabric. If this cannot be done, do sample testing as a means of having a consistent outcome of different fabrics.

Bumping or Vibration of the Press.

Cause:

Excessive vibration or movement of the heat press (a result of inadequate installation or poor stability) can cause the transfer sheet to move resulting in blurred images on duplicated images.

Fix:

The heat press must be ensured so that it is stable, level and properly calibrated. The pressing should not have any unnecessary movement.

How to Identify Ghosting in Sublimated Sportswear

• The ghost can be mostly in the form of blurred and dim pictures or overlaps. To a great extent it is effectively conveyed in the areas of logos, designs and text. Look for:
• Atypical scenery (black lines or shadows).
• In the non-strauss road prints where the lines of the design are not straight.
• Color gradation Movement rather than original or rather distant.

Step-by-Step Guide: How to Avoid Ghosting in Sportswear Sublimation

Prepare the Fabric & Panels Correctly

How-to:

• Such features as warings are to be observed: cloth to be clean and water off.
• Wipe the garments to remove the wrinkles and drops of water.
• The straightening of the panels is followed subsequently by the pressing of the panels.

Select the Choice of Transfer Paper and Inks to be Used on Sportswear

How-to:

• The sportswear will also require printing to remove inking of colours, ghost printing on high quality and special sublimation paper and inks.
• You want an ink to the printer, and even calico.

Secure the Transfer Sheet Properly for Stretch Fabrics

How-to:

• Use the high tacks to fix the paper to avoid slipping of transfer sheet.
• Fasten the cloth with the help of the right clips or weights especially in stiff cloths like leggings.

Dial in Heat Operational Environment of Sportswear Manufacturing

How-to:

• Sublimate your heat press to 190-205 deg C.
• Change the pressure and time depending on the thickness of the fabric (e.g. mesh or solid fabric).

Manage Team Uniform Graphics Team Ink Saturation

How-to:

• Test different ink densities and compensate on the high-density parts.
• Engaging in light applications of ink in large areas or backgrounds should be carried out to enable one is not over saturated.

Remove Transfer Paper Correctly

How-to:

• Next allow transfer paper to dry and then transfer.
• One must peel the paper off in a very light way so that it does not smear or ghost.
• Ghosting is a problem that is difficult to avoid with sportswear.

Troubleshooting Ghosting on Sportswear

For Polyester Jerseys

Set heat press and ensure that all the jersey is pressed to the desired level of pressure. Ghosting is a result of bad quality of sublimation paper.

For Mesh or Pinhole Fabrics

Mesh fabrics are also highly susceptible to bleeding of ink. Use a low-tack transfer paper and ensure that there is even out pressure when pressing.

In the case of Leggings and Compression Wear.

Stretch-specific setups are required to use compression clothes. You should also ensure that you pre-press the cloth to remove the moisture and the ink of lighter density should be applied on the stretch parts.

With Regard to Sublimated Hoodies and Jackets

Check the seams and the zippers in such a way that the ghosting will be eliminated on the edges. When using thicker fabrics, be sure to press with an adequate duration of time and use high heat levels.

Recommended Tools & Products for Anti-Ghosting Performance

Mistakes Sportswear Manufacturers Should Avoid

Low-Quality Inks:

 Poor quality inks may be used, which could cause the poor color accuracy and ghosting. I would never compromise on high quality sublimation inks that are applied on performance fabrics.

Inconsistent Heat Press Settings:
Due to inconsistency in pressure and temperature, inconsistent prints are attained. It is always good to run your press at a new batch.

Neglecting Fabric Type:

 Depending on the environment, there are different fabrics, which need different environments. Prepare piece of fabric samples of the test and set.

Omitting Pre-Pressing:

Pre-press cloth to remove wrinkles and moisture before sublimation in order to avoid ghosting and loss of adherence of color.

FAQs

Is more ghosting occurs on dark or light sportswear colors?

Ghosting also occurs more on the darker fabric as they have more shadows. Ghosting is also possible in light garments to a lesser level.

Can four-way stretch athletic fabrics increase the risk of ghosting?

Four way stretch materials will not only deform when pressed but will ghost when fine tuning is not done on the pressure or heat settings.

Is rotary heat pressing better than flatbed presses for avoiding ghosting?

Yes, rotary presses achieve reduced variance in heat and pressure that reduces possibilities of ghosting on the highest batches.

How do humidity levels in the factory affect sublimation outcomes?

When humidity is present in the ink, the ink is likely to be unevenly transferred which gives an irregular print. Optimally it works in a factory with a humidity level in the range of 40-60.

Does ghosting occurs in a roll to roll of the sublimation that takes place before the cutting of cloths?

Yes, roll to roll sub-lemation can ghost in case the cloth is not prepared and aligned correctly during the printing stage.

Do sports jerseys with mesh side panels ghost differently from solid fabric?

Yes, mesh displays tend to absorb ink unevenly therefore exhibited ghosts cannot but manifest themselves in those areas.

Can I sublimate sportswear multiple times without increasing ghosting risk?

In case of repeated occurrence, sublimation may cause ghosting. Checks and prepare set ups when needed.

What printing profile is best for large gradients used in team uniforms?

The smooth changes in colors and prevent the disproportionate prints are to be created with the help of a high-resolution profile with smooth transitions between colors.

Competitiveness: Goal Uniform, Achieving Ghost-Free Sublimated Sportswear

Goal Uniform designs high performance team wear that has been sublimated to perfection. We can provide a complete package of screen calibration to heat press scheduling, uniforms of the necessary quality that do not ruin the colors of your team and branding. And in case of issues in ghosting or you require more stable outcomes in the procedure of sublimation, Contact Us now. We will also help you produce flawless prints.