Ever wonder why we need to “warm the ink up” or “wet the mesh out,” either with a robust mixing or by printing some ill-defined number of shirts before we can run production with plastisol inks? The answer is due to the Perennial Plastisol Paradigm (PPP), in which the ink may be thick or thin but it is tacky, and exhibits excessive internal cohesion under applied shearing force to create a STICKY hand.
This traditional tack level is difficult to overcome. It is what 1) causes the need to “stir first” or waste a bunch of tubes 2) forces us to use a ton of pressure and run slowly, and 3) puts most of the flaws in the surface appearance and prohibits image registration.
Fortunately, there are now plastisol inks that are low tack without being runny and don't turn into plasti-bricks. As a rule, this grade of ink is typically shear-thinning so it clears the screen easily and mattes-down to a smooth, imprintable, high opacity surface.