Why Screen Printing is Outdated: The Environmental and Practical Case for Moving On

Screen printing has long been the go-to method for creating custom t-shirts and merchandise, but its time has passed. What was once seen as an accessible, low-cost way to mass-produce printed garments has become one of the least sustainable and least efficient options available in today's apparel landscape. The reality is clear: traditional screen printing is bad for the environment, labor-intensive, and logistically flawed for modern small-batch and on-demand needs. Worse still, it produces garments that often don’t last.

At Apparel & Beyond, we never used screen printing — and we never will. From day one, our business was built on sustainability, innovation, and quality. That starts with our printing method.

The Chemicals in Screen Printing

Most screen printers rely on plastisol inks. These are thick, petroleum-based inks that contain PVC (polyvinyl chloride) and phthalates. Both substances are flagged for their negative impact on human health and the environment. Plastisol inks do not dry on their own; they must be cured with high heat — often over 300 degrees Fahrenheit — which consumes large amounts of energy and requires industrial-grade ventilation. That process releases volatile organic compounds (VOCs) into the air, contributing to indoor and outdoor air pollution.

Even water-based screen printing inks — touted as a cleaner alternative — often require chemical solvents for cleanup and still involve the use of emulsion, screen reclaiming chemicals, and harsh cleaning agents. Those materials end up down the drain or in landfills, creating chemical exposure for workers and long-term environmental degradation.

The Water, Waste, and Labor

Traditional screen printing uses a lot of water. Each screen must be prepped, coated, exposed, washed out, and reclaimed after use. For multicolor designs, each color requires a separate screen. This means that even small jobs with detailed designs result in a disproportionately high resource load.

Waste is inherent in the process. Excess ink, test prints, and misprints pile up quickly, especially when working under tight deadlines or with detailed artwork. Mistakes are common, and errors typically mean starting over — with more ink, more time, more waste.

Labor, too, is inefficient. Screen printing is best suited for mass production runs where designs are simple and don’t change often. But for today’s customers, who often want personalized garments, short-run batches, or fast turnaround, screen printing becomes a cumbersome and outdated solution.

The Issue of Longevity

A common misconception is that screen printed shirts are more durable. While plastisol does offer initial vibrancy and a thick, raised print, it tends to crack and peel with repeated washing and wear. Because plastisol sits on top of the fabric rather than fusing into the fibers, its lifespan is tied to the flexibility and movement of the garment. Over time, this becomes a problem — particularly for activewear or everyday staples.

In contrast, our DTG (Direct-to-Garment) printing at Apparel & Beyond uses water-based pigment ink that chemically bonds with the fabric. The result is a softer feel, more breathable finish, and a print that moves with the shirt. It won’t crack, peel, or fade the same way a plastisol print will. And because the inks are water-based, the environmental footprint is significantly lower.

The Advantage of Digital Printing (DTG & DTF)

Unlike screen printing, DTG and DTF (Direct-to-Film) printing require no screens, no emulsions, and no pre-press setup. This allows for unlimited colors, detailed artwork, and rapid on-demand production without waste. We print what’s needed, when it’s needed.

DTG and DTF allow us to operate with minimal excess. We don’t bulk order blank garments unless there’s confirmed demand. We don’t waste shirts testing screen alignment. We don’t throw out gallons of ink from outdated runs. Our machines are energy-efficient, require no heat presses beyond standard curing, and allow us to produce a high-quality product without excessive water, chemicals, or electricity.

Better for the Planet. Better for Your Business.

If you're a small business, school, nonprofit, or community group looking to get custom apparel, your choice of printer matters. Choosing a DTG or DTF provider means supporting a cleaner supply chain, getting better quality products, and often enjoying faster turnaround. You won’t be waiting weeks for your order or hit with setup fees and minimums.

It also means your shirts will last longer, look better, and reflect your values. In an age of climate consciousness and growing consumer demand for responsible production, it pays to choose a partner who gets it.

At Apparel & Beyond, we go a step further. We operate under a Made-To-Order model, meaning nearly every item we produce is created for a specific customer. We average less than one bag of trash per month. Our inks are water-based, our cartridges are recycled, and even our racks and furniture are upcycled or locally sourced. We curate and sell higher-end secondhand garments as part of our commitment to sustainable fashion. And we’re proud to serve customers who want more than fast fashion or flashy brands. They want better.

The Bottom Line

Screen printing had its moment. It helped launch the custom apparel industry. But in 2024 and beyond, we must think differently. The environmental costs are too high, the results are too inconsistent, and the process is no longer aligned with how people shop, print, and live.

Modern digital printing methods are scalable, sustainable, and superior in nearly every way that matters. Whether you’re outfitting a staff, printing for an event, or starting a brand, there’s no reason to keep supporting outdated methods when better ones exist.

We never screen printed. And now you know why.

Apparel & Beyond isn’t just a custom print shop. We’re a purpose-driven business redefining what apparel can be — for you, for the planet, and for the future.