General enquiries
What is the most common flag size?
The most common size flown in NZ is the 2 yd at 6 x 3’ or 1800 x 900 mm. We supply country flags in 2 ½ yd and 3 yd as well as 1 ½ yd and 1 yd.
A flag can be any size. Generally what is specified is the ratio of length to depth. Viz for NZ 2:1 is specified- it is to be twice as long as it is deep. The flags we make for the Auckland Harbour Bridge are 7000 x 3500 mm- so all different sizes but the same ratio. Other countries specify different ratios eg Switzerland 1:1 but in NZ we make the Swiss flag 2:1 to be consistent with other flags flown in here. USA specifies 19:10 just to be different!
Other standard sizes are 1 yd (900 x 450 mm); 1 ½ yd (1350 x 675 mm); 2 ½ yd (2250 x1125 mm) and 3 yd (2700 x 1350 mm).
How is a flag attached to a flagpole halyard?
Fittings/Fixing are those items attached to the heavy duty header of the flag so it can be attached to the flagpole halyard. Most frequently used methods are Rope & Toggle (R&T) and sister clips (s/cs). Other methods include eyelets (for clips), rope top and bottom, closed sleeve, soft loops etc.
What are the size limitations for printing flags?
Because traditional screen printing screens were set up for National flag sizes then so Corporate flags tend to follow in the same ratio of 2:1 and size typically 1800 x 900 mm consistent with the most common size NZ flag flown. The reality is a flag can be any size and any ratio fit for purpose with the exception of a country flag where their ratio typically follows the ratio set for the host country flag.
With the advent of digital printing and alternate shaped flags such as the Curve Top and Teardrop other parameters determine size-eg the size of the flexible pole components available, the size of the pole base (for stability), the width of available printing media, width of digital printer print bed. Of course several panels can be seamed together to make a flag or banner deeper than the fabric width (harbor bridge flags are cut from 2 m fabric). We can digitally print up to 2.4m but limited fabrics only, 3.2 m onto PVC.
With flags, sizing is nominal. For example a 2 yd at 1800 x 900 mm + or – 5-10% would be normal and acceptable. Teardrops and Curve Tops are described by their heigh and maximum width.
What does a” print ready” file mean?
Print Ready file- a file that is ready to print. It could also be called “final art”. Should also incl. bleed -that extra fabric required for hems and other finishing.
The most common file type we use is a pdf. The hi res pdf should be saved as an editable version by the designer. This retains layers for easy colour matching. (Some pdfs are lo res and so unsuitable). eps and ai are typically a copy of the original file from the designer and the pdf is a non editable version of the original. tiff is often about add-ins like photographs. A jpg best represents a colour visual- a snap shot of the design to ensure all the elements are present- should be requested in the first instance.
Even pdf’s are not bullet proof. Sometimes files get corrupted on the internet- things drop out or colours change so a colour visual is good to ensure completeness of the file to be printed- prudent if you are not familiar with what the file looks like.
We can print photographs. Most modern digital cameras will capture a suitably hi res image if set to the biggest picture size (number of pixels). Note if pic is taken at too low a res we can do nothing to increase the resolution.
How can I tell if my pic or image is suitable?
Submit it and we will confirm for you.
Ideally we want the file to be as near to print ready as possible – file should be 300 dpi; at any lessor resolution then file may not be suitable. Also send an alternative file format (jpg) as a colour visual. We really only want to add bleed and colour match to the reference colours supplied.
NB a jpg file is almost certainly not suitable for printing. Similarly gifs- these are tiny files that feature in web sites etc.
Files can be delivered by attaching to emails, on disc or memory stick and large files sent via YOUSENDIT.
We have the capacity to copy or trace unsuitable files into new , suitable quality files but this is a chargeable extra and it is always difficult to guesstimate in advance just how much the redraw will cost.
Traditionally flags are finished with hems all round. At the head (that end immediately adjacent to the flagpole) a heavy duty fabric heading is added. Into the heading is sewn the cord for the fittings/fixings to be attached to.
Hot knifing is another way to form an edge/hem- fabric is cut away with a “hot knife” using a non burnable underlay (glass sheet or metal table) and a straight edge. Commonly used on the exposed (flying) edges of street banners- quick but not necessarily cheaper or better but satisfactory for short term exposure of street banners (say 4-6 weeks).
Keyline- this is a very feint outline added to an image at time of final preparation to be used after the blank is printed as a trimming or cutting line. Important where colour does not run to the edge eg a central logo on a white field or background. Remembering we typically print onto white fabric (so white in an image is not printed at all).
What type of file is required for printing?
A simple file spec. is 300 dpi (dots per inch); vector based (infinitely scalable without distorting) and fonts turned to paths or outlines ( any text is represented in the file as if it were a shape).
In addition to a suitable format file colours must be defined. Colours are defined by the Pantone Matching System, PMS numbers.
Every computer screen will show the same file as a slightly different shade (desk top printers will output similarly). So if PMS not defined please supply a physical printed sample eg letterhead or business card that displays approved colours. Or get some other physical sample(s)- clippings from magazine for each colour.
We will produce an A4 patch for an approved job as a final reference before printing.
Note CMYK and RGB and others are also colour referencing systems but they are not something that can be “eyeballed”. How a given CMYK mix appears on paper will be a function of both the program that created the file and the printer it was produced on.
Do you print on to natural Fabrics?
We do not print any natural fabrics (cotton or linen). The vast majority of printed fabrics are polyester based. Nylon is sometimes used as it is cheap and available in a large range of colours. Nylon is used as a coloured base to screen print one more colour onto.
What is the most common material used?
Polyknit is the most common flag fabric by far. As its name suggests it is of a knitted construction. There are various weights/grades and we typically us around 110 gsm. Lighter weights will give higher strike through (intensity of colour as viewed from the non printed side) but will not last as long in the wind.
Polybunting is a heavier thread, woven polyester fabric. No question it lasts longer than knit before its hems fail but once they fail the weave tends to fall apart. Hence repair is needed soonest whereas with knit the fabric slowly abrades away so there is little difference if one is prepared to put up with a non standard sized flag. The other advantage of bunting is that as it is woven it has “holes” in it so carries less dye per sq. m. As such the printed item is matt in finish and so looks much more like a natural fabric. Knit has a sheen which is not appreciated by some. Most fabrics have a bias which allows them to be more simply cut into certain shapes- some sit better.
Waratah is a brand name of a woven fabric great for making banners. It is strong and optically white.
Polysatin is typically used where a complex image is to be viewed close up such as Roll-Up banners at exhibitions and events. We have a double sided fabric best used for Teardrops and banners- items that do not flap. Earlier versions were quite cream/grey cf crisp white which tended to deaden colour. Double sided is used where there is a requirement to have a positive image both sides of the fabric or different images each side of the fabric with no strike through.
PVC is used for heavy duty banners- those installed long term outdoors. It is the toughest printed fabric but does not like flapping- flapping breaks its surface. Similarly it must be rolled for storage, not folded, and even if rolled but then crushed the skin will break at the crease line. Vinyl is a similar product- PVC adhered to a cloth backing. Typically used for upholstery. This media is often referred to as banner vinyl, just to be confusing. PVC solvent printed banners are for viewing at a distance- print resolution is less than onto fabric, they weigh 4x as much (around 550 gsm) but most PVC based media can be printed up to 3200 mm across so great for one piece large banners (eg billboards) . There are special PVC media such as back lit and mesh for special applications.
Our “fabric” printed media is sometimes referred to as soft signage.
Most (non PVC) digital printing media is around 1500 mm wide. We can print some media up to 2400 mm but there is limited media available at this width.
Wind is the major enemy of flags and the higher the wind speed then the faster the deterioration. To extend flag life it is advisable to bring flags in at night when they cannot be seen ( unless floodlit) and consider not putting them out if high winds are expected on that day. When your flag shows wear, and it will, then effect a repair soonest. Flags can be washed in a normal wash cycle. To keep your flag looking bright it is best to wash sooner rather than trying to bring it back from heavy satining.
The clock starts only when the print file is signed off for printing. When thinking of buying flags consider the design as well as how many and at what price so a final design can be approved soonest. If you cannot supply final art then prepare a sketch (we need only a hand sketch- not an artist’s impression) noting fonts to be used, colours, relative sizes and logos to be incorporated. Send as a scanned file or fax along with a file of the logo.
We quote 5-6 working days for digital print jobs and 2-3 weeks for screen printing. We can achieve faster delivery times so tell us your deadline and we will commit to meeting it.
Which is better Screen printing, or Digital printing? Why?
Screen printing is the traditional method of printing flags. Prior to suitable printing methods being available flags would be made by hand using applique.
Digital printing utilises current technology. It has many advantages but also shortcomings compared to the traditional method.
Generally only polyknit and polybunting are used for screen printing but digital print utilises both these a wider array of polyester based fabrics to achieve specific outcomes.
The starting point for both processes is a high resolution digital file. The essential differences are that digital outputs at higher resolution achieving much finer detail in the print (on fine surface fabrics such as polysatin photographs can be authentically reproduced) whereas screen lays down more dye. Hence screen is best for coarse detail and spot colours where equal colour intensity on both sides of the fabric is important. Digital achieves best with fine detail and great colour on the printed face. For digital to achieve full colour on both sides we need to print both sides which has cost implications and size limitations.
Screen has set up costs- a screen must be made for each colour to be printed so usually delivery time is longer. The same number of screens are required for 1 or multiple prints so screen printing remains the cost effective method to make larger quantities of flags. For fine detail and quicker delivery then digital is the optimal method of printing, especially if only a single sided print is required (banners). The lower colour intensity of the digital process non printed side can be overcome by utilising additional processes, see above).
When evaluating printed fabric consider what it will look like in situ. It is unrealistic to compare print quality at arms length when the intention is to fly the flag from a pole. Likewise a banner to be observed close up at a Trade Show demands a superior quality print outcome.