“Quite often the cost price parameter is used as the decisive factor for whether or not to switch to digital textile printing. This focus on purely the cost price per printed meter might be incomplete because more factors influence the choice between rotary or digital for your specific project” Jos Notermans - SPG PRINTS
GUEST ARTICLE WRITTEN BY JOS NOTERMANS OF SPGPRINTS
The difference in costs between rotary screen textile printing and digital textile printing is interesting, to say the least. This counts especially for companies that combine both printing methods or printing companies that are in a transition phase to digital printing.
In a previous article, we mentioned that rotary screen printing becomes more economical as the run lengths get longer. This raises an interesting question. Is there a break-even point at which the costs of digital and rotary screen printing cross? And if so, does that mean rotary screen printing is always the better choice for run lengths beyond this break-even point? In this blog, I will explain which factors determine where this break-even point occurs.
Expectation versus reality
As a provider of both print methods, SPGPrints often gets questions about the break-even point. There seems to be an implicit expectation that there is one specific answer to this question, but unfortunately this is not the case. Yes, there is a break-even point between the cost of digital textile printing and rotary screen printing. However, this break-even point differs per print job, as there are a couple of factors that affect it.
Quite often the cost price parameter is used as the decisive factor for whether or not to switch to digital textile printing. This focus on purely the cost price per printed meter might be incomplete because more factors influence the choice between rotary or digital for your specific project. For example, rotary screen printing might be the better choice for your design in terms of run length, but if the design is too complicated or has a very long repeat length, the only option for this design might be to print it digitally.
There are a total of 6 factors to be reckoned with. These are all related to run length and design. In the next chapter, we take a look at these factors with the help of visualization.
The break-even point visualized
To understand the break-even point, we need to understand what causes the cost difference between rotary and digital. With rotary screen printing, there are the costs of the screens and the engraving of the screens. These start-up costs depend on several factors. The start-up costs are shown on the vertical axis in Figure 1. Digital textile printing does not have specific start-up costs, which results in a straight line if we map this on the horizontal axis: the run length. (Note: both printing methods will probably require initial software work on the digital file; this is assumed more or less equal in both methods).
Conventional printing has higher preparation costs, but lower printing costs than digital printing. As a result, the line of rotary screen printing is a descending line. The break-even point is where both lines cross. This break-even point shifts to longer run lengths when the start-up costs get higher.
Both the horizontal (run length) and vertical (price per meter) axes depend on three factors, explained below.
1.The horizontal axis: run length
The total amount of printed meters you are going to produce of a design determines for a large part the cost of both printing methods. As rotary screen printing is a descending line, it becomes more financially attractive as the printing length increases, so past the break-even point rotary screen printing becomes the most economical option.
1.1 The assignment at hand
Logically, the first factor that determines the run length is the print job itself. What does the customer want exactly? How many meters of the design are needed? And how big is the design itself? The original print job determines the run length and thus a large part of whether or not the break-even point is reached. Therefore, when choosing between rotary screen printing and digital textile printing, the most important question to ask is: “how many meters do I need to print?”
1.2 The number of colorways
The run length of the original query can be increased with different variants of the same design, called ‘colorways’. For example, does the customer need the same design in another color? If you are going to make the same design in more colorways, this lengthens the total run length. This means that with multiple colorways of the same design you can ensure that you will cross the break-even point in the particular job in favor of rotary printing.
Important to realize is that this is possible with the same screens in rotary screen printing. This means that the start-up costs do not go up when deciding on an extra colorway. In digital textile printing each colorway costs the same, so more colorways of the same design can make rotary screen printing cheaper thanks to the long run length.
1.3 Repeat orders
This is quite an intangible parameter, but repeat orders can also determine whether you cross the break-even point. Do you expect to get repeat orders of the same design? If you can estimate this at an early stage, these repeat orders should be added to the calculation of the total print job. In rotary screen printing you can use the same screens again, which means the total run length with these screens will be a lot longer due to the repeat job(s). This is a very important factor to take into account in the initial calculation of the break-even point.
We understand that this cannot always be estimated in advance. If you are not sure whether there will be repeat orders, it is logical to ask whether it is possible to start with digital textile printing and switch to rotary screen printing in a later run. This is possible, but there are some things to take into account before deciding if it is possible in your specific case.
2.The vertical axis: Total cost per meter
On the vertical axis, we see the total cost per meter. At the origin (the run length is 0), this equals the start-up costs. In Figure 1 we have put two different rotary printing cost situations as examples. The red line is a rotary printing job with only a few colors, so it has relatively low start-up expenses and therefore already reaches the break-even point with digital at 1,000 meters. The yellow line represents a rotary printing job with many colors, so it has higher start-up costs and therefore becomes more expensive than digital printing for the first 5,000 meters. Please note that these are examples and the exact break-even run lengths can be different in the case of your company and print jobs.
As you can see, start-up expenses are particularly important in rotary screen printing, as they have a great effect on the final break-even point. But what determines how high these start-up expenses are?
2.1 Amount of colors, screens and printing paste
The first important question regarding start-up expenses for rotary printing is: how many colors are you going to print? The usage of more colors means that you need to buy and engrave more screens so you have more costs.
An often neglected fact of printing with more colors in rotary is that you also need to prepare more printing pastes. The key challenge in that is: how much paste do you prepare for each color? After all, a shortage of printing paste is tricky, as mixing extra paste with exactly the same color at a later stage is difficult. That's why it is very likely that in practice you prepare too much printing paste. This means that you are most probably left with paste that needs to be disposed of in a carefree, chemical responsible manner. This is an unfortunate - but very important - side-effect and means extra costs that have to be taken into account.
2.2 Type of screens: challenging designs
In addition to the number of screens required, the type of screens also plays a major role in your start-up expenses. Very detailed designs require higher mesh screens like the SPGPrints NOVA screens, which are more expensive than lower mesh screens. In short, the difficulty of the design determines how expensive the screens you need are.
2.3 Quality of screens
A rotary screen does not have eternal life. So especially when you are planning to print long run lengths, it is wise to buy a high-quality screen that ensures you can print that whole run with the same screen. You don’t want to run into the situation that when 80% of the print job is done, the screen breaks or becomes unusable for other reasons. Then you have to stop your production because a new screen must be bought and engraved. This means an extra ‘start-up expense’ during the print job.
Rule of thumb for your break-even calculation
To make a trustworthy break-even calculation that allows you to make a good trade-off between rotary screen printing and digital textile printing, you must look at all the factors mentioned above. After all, the turning point where rotary becomes cheaper than digital per meter is related to several factors that all need to be taken into account.
I explained three factors that determine the run length and three factors that determine your start-up expenses. Together, they determine the run length of your print job at which your break-even point occurs. Below that break-even point, digital printing is cheaper. Above that break-even point, rotary printing is cheaper. But as mentioned in the beginning, the break-even point is not a fixed number, as it depends on your company and even your print job.
As a rule of thumb, run lengths below 1,000 meters are in general cheaper to print digitally.
Orders over 5,000 meters are almost always less expensive with rotary screen printing. Between 1,000 and 5,000 meters, the factors explained above play an important role in your decision. As discussed, the break-even point differs per print job. Take all factors thoroughly into account in your consideration, when your expected run length is between 1.000 and 5.000 meters, which is quite common in many print jobs today.
In our Strategic Guide you can read more about the transition to digital textile printing and what this involves.
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A Century of Textiles, and an Ever-changing World
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The Market Gap that Changed Everything
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Is the Textile Market Finally Recovering?
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South Normanton - UK – November 2026 - As the out-of-home advertising market continues its rapid expansion, Sun Chemical is driving the industry's shift toward water-based ink technology with its Streamline™ Toccata range, engineered to meet the rising demand for high-quality, durable graphics while reducing environmental impact.
London, UK – November 2nd 2026 – Spandex UK has today announced a new partnership with HP, bringing HP Latex printing technology to its customers across the UK. The collaboration marks a significant expansion of Spandex's large-format hardware offering, giving its customers greater choice across print technologies.
The initial line-up under this partnership will include the HP Latex 630, 730 and 830 series. These additions build on Spandex's existing portfolio, reinforcing its commitment to equipping sign and display professionals with the tools they need to stay competitive in an evolving industry.
Malvern – Worcestershire – November 2026 Vivid Laminating Technologies has announced that PB Signs, a leading UK print and signage specialist, has chosen its multi-award-winning Velobade Nexus for use across its production operations. The decision follows a thorough review of the market, with PB Signs selecting the Velobade Nexus as the finishing solution best suited to its high standards of craftsmanship.
Speciality print leaders from five Southern European countries will meet in Porto next month for the eleventh FESPA Southern European Congress, taking place on 11–12 November at HF Ipanema Porto, Portugal.
The two-day event, which is organised by five FESPA member associations – FESPA France, FESPA Italia, FESPA España, APIGRAF (Portugal) and the FESPA Hellas Association (Greece) – gives members of the community in Southern Europe the opportunity to benchmark their own strategies against peers facing similar conditions, as well as compare notes with neighbouring markets on customer expectations, workforce shortages, investment and new technology.
Batley, West Yorkshire – October 2026 – Roaches International, a member of the British Textile Machinery Association (BTMA), has dispatched its largest integrated order for textile laboratory equipment to date.
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Mortsel, Belgium – October 29th 2026 – Agfa Inkjet Solutions has announced Experience Day 2026, a hands-on event dedicated to demonstrating how advanced inkjet printing and precision finishing can work together within a single, integrated workflow.
The event will take place on Thursday, 26 November 2026, from 09:00 to 15:00 at Agfa Headquarters in Mortsel, Belgium.
Developed in partnership with Kongsberg Precision Cutting Systems, Experience Day 2026 will give print service providers a first-hand look at how combining print and finishing technologies can boost productivity, broaden application possibilities, and open up new business opportunities across sectors including signage, display, packaging, and corrugated production.
Balrothery, Ireland – October 2026 – Retink Graphics has added a second Epson SureColor R5000L latex printer to its Balrothery production floor, supplied by digitalprint.ie.
The investment follows strong returns from the company's first R5000L, which the team says paid for itself before they decided to expand.
Tübingen, Baden-Württemberg – October 2026 - The CHT Group has announced the expansion of its dyes portfolio with two new additions: BEMACID Brilliant Blue F-WN for polyamide and wool, and BEZAKTIV Solar Yellow ONE for flexible dyeing processes.
The launch reinforces CHT Group's commitment to delivering high-performance, sustainable colorant solutions for the global textile industry.
Both new dyes address growing demand among textile manufacturers for products that combine color brilliance, process reliability, and responsible formulation.
Staffordshire, UK – October 2026 – Staffordshire Signs & Graphics Ltd has announced the installation of a new DLI-3325 flatbed printer, supplied by China Print Supplies UK Ltd.
The investment marks a significant step forward for the business, enhancing its production capabilities and expanding the range of signage solutions it can offer customers.
The installation follows months of careful planning, with the new machine now in place and undergoing fine-tuning and staff training ahead of full commissioning
Corby – Northants – October 2026 – Keencut Ltd, a leading innovator in the cutting and finishing equipment industry, has today highlighted its Evolution3 Lift & Hover technology, a breakthrough system designed to make material positioning faster, easier and more accurate than ever before.
The new technology allows operators to adjust, align and achieve perfect positioning with precise control, all through simple single-person operation.
By streamlining what has traditionally been a multi-step, often cumbersome process, Keencut is addressing a long-standing challenge faced by professionals across the sign-making, graphics and framing industries: achieving exact cutting precision without compromising on speed or efficiency.
Istanbul – Turkiye – October 2026 – Optimum Digital has announced that Kilim Home, an established Turkish carpet manufacturer serving international markets, has invested in its direct-to-carpet printing technology.
The move strengthens Kilim Home's production capabilities and marks a significant step forward in the company's ongoing embrace of innovation within digital carpet manufacturing.
Frankfurt am Main, Germany – 27 October 2026 – Heimtextil, the international trade fair for home and contract textiles, has announced the launch of the Functional Futures Lab, a new showcase curated in partnership with Future Fabrics Expo.
Taking place from 12 to 15 January 2027 in Hall 4.1, the exhibition will spotlight materials engineered to meet the evolving functional demands of architecture, interior design and hospitality, from thermal regulation to flame resistance and durability.
The Functional Futures Lab will present both visionary prototypes and commercially available solutions, with each exhibit's stage of development made transparent through Technology Readiness Levels
Shanghai, People's Republic of China – October 2026 – KARL MAYER will present a comprehensive portfolio of advanced warp knitting and warp preparation technologies at ITMA ASIA 2026, taking place from 20 to 24 November at the National Exhibition and Convention Center (NECC) in Shanghai.
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Bolzano, Italy – 26 October 2026 – Durst will participate as Leading Sponsor at Viscom 2026, taking place on 28 and 29 October at Allianz MiCo Milan.
In the year marking its 90th anniversary, the South Tyrolean company returns to the leading event for the Italian visual communication market with a new format, a new location, and the Italian debut of a new printing technology.
Durst's presence at Viscom underscores the company's commitment to maintaining close dialogue with customers, prospects, and industry professionals.
Clay Cross – UK – July 2026 – Resolute highlights its new DTF Pneumatic Twin Platen Heat Press, a professional-grade heat press designed to help print shops increase output, improve consistency, and reduce downtime across high-volume production runs.
The machine's dual-platen design allows operators to prepare the next garment while the current one is being pressed, significantly reducing idle time and increasing throughput.
This makes it particularly well-suited to print shops running large direct-to-film (DTF) and transfer print operations, where speed and consistency are critical.
Pattern Room Launches New Pattern Room Experience, Making Online Design-to-Pattern Faster Than Ever
Victoria, Australia, 27/10/2026 – Pattern Room, the online pattern-making studio founded by Australian pattern maker Julia Watts, today announced the launch of its updated platform, introducing a new guided design pathway, an in-house sampling service, and an expanded catalogue of styles for apparel businesses worldwide.
The update is designed to make it faster and easier for designers, garment technicians, and manufacturers to move from concept to production-ready pattern, without the friction that has traditionally slowed the early stages of garment development.
Athens , Greece – 23 October 2026 – UFABRIK has extended its European distribution network into Greece with the appointment of TSEKMERES GS, an established supplier to the country's textile, screen and large-format digital printing industries.
The agreement brings UFABRIK's digital textile portfolio to a market where UV and Latex technologies remain dominant, but where dye-sublimation is emerging as a significant area of potential growth.
The partnership will focus on providing high-quality textiles for silicone edge graphics (SEG) applications, alongside a wider substrate offering for the Greek market.
São Paulo, Brazil – October 2026 – FESPA has announced that FESPA Brasil 2027 will take place from 1 – 4 March in the Blue and White Pavilions of Expo Center Norte, São Paulo.
The leading digital printing exhibition will bring together the sector's biggest global players to showcase the latest solutions across packaging, textiles, signage, and personalised products.
As one of the most visited exhibitions organised by FESPA, FESPA Brasil 2027 will give visitors access to complete solutions and technological innovations spanning print shops, packaging and labels, textile printing, personalised products, 3D printing, and signage and wide format, among other sectors
New York City, USA, October, 2026 – NedGraphics, a global leader in textile and apparel design software, today announced the official launch of NedGraphics 2027, a major software release designed to bring creativity, technology, and production closer together through a more connected and flexible digital ecosystem.
At the center of NedGraphics 2027 is OPTINEDCloud, a new cloud storage and asset management environment integrated across key NedGraphics applications.
OPTINEDCloud gives design, approval, and production teams a centralized space to store, organize, visualize, share, and manage product development files.
Mönchengladbach, Germany – Monforts will showcase its latest advances in finishing, coating and energy-efficient processing at India ITME 2026, as the region's textile manufacturers increasingly look beyond volume production towards higher-value fabrics.
The German finishing machinery specialist will exhibit in Greater Noida , India at stand A5 in Hall 1 from December 4-9.
Milan, Italy – October 22nd 2026 – Agfa Inkjet Solutions today announced it will present its award-winning Jeti Bronco H3300 HS live at Viscom Italia 2026, taking place 28–29 October at the Allianz MiCo Convention Center.
Visitors can see the hybrid wide-format printer in action at Stand 8 B17/C20, where Agfa will demonstrate its capabilities for sign and display businesses seeking greater productivity without compromising on image quality.
The 3.3-metre Bronco H3300 HS delivers print speeds of up to 450 m²/h while maintaining high image quality, combining the flexibility to handle both rigid and roll media in a single hybrid platform.
Berlin, Germany – 21 October 2026 – NVIDIA today announced that Europe's leading ecosystem partners are adopting the NVIDIA DSX™ AI Factory Platform to build AI factories that minimise water consumption for cooling and use less power for the same AI output.
The platform also helps partners bring new capacity online faster and adapt workload power consumption to support grid reliability.
NVIDIA DSX is a full-stack AI factory reference architecture, co-innovated with the world's leading infrastructure companies, in which compute, networking, storage, software, power and cooling are codesigned as one system.
East Sussex, UK – October 2026 – Vivid Laminating Technologies has announced that Pureprint Group, a leading print and marketing services business, has selected its multi award-winning Veloblade technology for use across its operations.
The decision underscores a shared commitment to innovation and efficiency within the print industry.
Imst – Ostreich – October 2026 – DyStar, a global leader in textile chemistry and innovative solutions, has announced its pivotal role in helping Textildruck Imst (TDI) achieve successful certification of the German "Multitarn" camouflage print.
The achievement, reached within a matter of months despite an ambitious timeline and exceptionally stringent requirements, enabled production to commence on schedule as part of a strategic collaboration with Getzner Textil.
The certification process demanded rigorous standards across colour performance, durability, infrared signature, and safety compliance.
From the outset, DyStar supported TDI by supplying the necessary products, technical expertise, and hands-on application support required to meet these demanding benchmarks.
Milan, Italy – October 2026– Epson will present its latest advancements in signage, UV printing and textile customisation at VISCOM 2026, taking place at Allianz MiCo Milan on 28-29 October.
Visitors can find Epson at Gate 3, Stand G14, where the company's specialists will demonstrate how its newest technologies are helping businesses expand into high-value applications through superior print quality and precise colour management.
As visual communication and personalisation markets continue to evolve at pace, Epson is positioning itself at the forefront of that change.
Leicester, UK – October 2026 – VeriVide is an official RAL Distributor in the United Kingdom, giving UK designers, specifiers and manufacturers direct access to the complete range of RAL colour standard products.
The appointment reinforces VeriVide's commitment to supporting the architecture, interior design, and industrial design sectors with reliable, globally recognised tools for accurate colour communication.
South Normanton – UK – October 2026 – Sun Chemical, a global leader in printing inks, coatings, and pigments, today reinforced the importance of looking beyond colour when selecting dyes for printing inks, urging formulators and manufacturers to weigh performance data alongside colour accuracy to achieve reliable, long-lasting results.
While colour remains a defining factor in dye selection, Sun Chemical emphasises that performance properties are equally critical to a dye's overall suitability for an application.
These include lightfastness, which is shaped by dye concentration, binder composition, substrate, and testing conditions; resistance properties, such as bleed resistance and over-lacquering resistance; and migration behaviour, which can vary depending on the substrate, coating, and storage conditions.
United Kingdom – October 2026 – Textile Skills Centre has announced a new Design to Print Competition in partnership with Prinfab, the UK's leading digital fabric printer.
The competition invites UK schoolchildren aged 5 to 18 to submit original textile designs or artwork for the chance to see their work professionally printed onto fabric.
The initiative aims to give young designers a tangible, industry-standard outcome for their creative work, while introducing them to the practical realities of textile design and digital printing.
Telford, UK – October 2026 – Ricoh UK has announced the return of Print Evolution Live, its flagship industry event, for a fourth consecutive year.
Taking place on 10-11 November 2026 at Ricoh's Telford site, the event will once again bring together leaders from across the print sector to explore the strategic shifts shaping the industry's future.
Karachi – Pakistan – October 2026 – ZIMMER AUSTRIA successfully concluded its participation at IGATEX PAKISTAN 2026, one of the region's leading exhibitions for textile and garment technology.
The event highlighted a growing shift among Pakistani manufacturers toward high-value technical textile production, a trend that aligns closely with ZIMMER AUSTRIA's innovative solutions.
Throughout the exhibition, ZIMMER AUSTRIA demonstrated the capabilities of its #magnoroll and #colaris technologies, both designed to support manufacturers moving into advanced technical textile segments, including coating, printing, and specialty fabric production.