5 Tips When Choosing An Emulsion
Whether you’re just getting started or have years of screen printing under your belt, choosing the right emulsion is one of the most important decisions you’ll make in your shop. A good emulsion sets the foundation for sharp, durable stencils and efficient production.
But not all emulsions are created equal—some are better suited for water-based inks, others for plastisol; some reclaim more easily, others offer unbeatable durability. In this post, we’ll explore the top five things to look for in an emulsion and highlight five of our most popular emulsions to guide your selection.
WATCH VIDEO: Top Textile Emulsions with the Emulsion Guru
How to Choose the Right Emulsion: 5 Key Features to Consider
At Chromaline, we’ve developed a wide range of premium screen printing emulsions and economy screen printing emulsions tailored to different printing environments, ink types, and shop sizes.
1. Ink Compatibility
The first—and arguably most important—thing to consider when choosing an emulsion is ink compatibility. Not all emulsions are resistant to every type of ink, and using the wrong emulsion can lead to stencil degradation, poor edge definition, or complete stencil failure mid-run.
Water-based and discharge inks, for example, are harsher on emulsions and require higher water resistance, while plastisol inks are more forgiving. Solvent-based inks, often used in industrial or specialty printing, also demand their own level of chemical resistance.
Featured Emulsion: CP Tex is a diazo-based emulsion specifically formulated for use with both water-based and discharge inks, as well as plastisol. With 42% solids, it builds a strong stencil quickly and is known for its durability—even in long runs. Some customers report up to 75,000 impressions off a single set of screens when used correctly. CP Tex is a top pick for textile printers needing a reliable, high-performance option for water-based and discharge jobs.
2. Exposure Speed & Latitude
Exposure time can dramatically impact your workflow. Faster exposure means less time spent burning screens, which is ideal for high-volume shops. But exposure latitude—how forgiving the emulsion is to under- or overexposure—is just as important. A fast emulsion with a narrow latitude demands precise exposure control, while a slower emulsion with wide latitude offers more flexibility.
Featured Emulsion: ChromaBlue is a pure photopolymer emulsion that exposes extremely fast—a huge advantage when speed is your priority. With 50% solids, it offers thick stencil build with minimal coats. But it’s important to note that ChromaBlue has a narrow exposure window, meaning it requires well-calibrated exposure units and consistent process control. It’s ideal for shops using plastisol inks and looking to speed up screen production without sacrificing detail.
3. Stencil Durability & Ink Resistance
A durable stencil holds up through long production runs, aggressive squeegee pressure, and even abrasive ink additives. The emulsion’s resistance to water, solvents, and UV exposure plays a major role in how well it performs throughout a job.
Featured Emulsion: Magna/Cure UDC-HV is our most popular dual-cure emulsion, offering broad ink compatibility and outstanding durability. It performs well with plastisol, solvent-based, UV-curable, and even some water-based inks, though it’s not as water-resistant as CP Tex or Hydro-X. With 35% solids, it requires slightly more coating than pure photopolymer, but makes up for it with its exceptionally wide exposure latitude and tolerance for less-than-ideal shop conditions, like light leaks or inconsistent humidity. If you need a flexible workhorse emulsion that can handle just about anything, UDC-HV is it.
4. Shelf Life & Reclaimability
Not every shop burns screens daily, so it’s important to consider how long your emulsion lasts on the shelf—and how easy it is to reclaim. Diazo and dual-cure emulsions typically need to be used within 4–6 weeks of mixing, while pure photopolymer emulsions can last up to two years unmixed. Easy reclaiming also reduces labor, saves water, and prolongs screen mesh life.
Featured Emulsion: Hydro-X (formerly Chroma/Tech WR) is a pure photopolymer emulsion engineered for water-based and discharge printing. With 46% solids and high water resistance, Hydro-X offers the performance of CP Tex but with the added benefits of photopolymer: no mixing required and a two-year shelf life. It also reclaims easier than many other high-durability emulsions, making it ideal for shops that want water-based durability without the mess and waste of shorter-lived emulsions.
5. Visibility & Registration Aid
Color might seem like a minor detail, but it can make a big difference. Emulsions with good transparency help with registration, especially when aligning multi-color jobs. If you're lining up your print on-press or using a vacuum exposure unit, an emulsion that's too dark or opaque can cause frustration and alignment issues.
Featured Emulsion: ChromaLime is a high-performance pure photopolymer emulsion formulated for plastisol inks. Its standout feature is its bright lime green color, which provides excellent transparency while still being easy to inspect for coating consistency and pinholes. What makes ChromaLime especially valuable is its humidity resistance—a game-changer during hot, sticky months when other emulsions struggle. If you’ve ever had your film positive stick to the screen during exposure, ChromaLime will be your new best friend.
Find the Right Emulsion for Your Workflow
Each emulsion has its strengths, and the right choice often depends on your shop’s equipment, ink types, humidity conditions, and production goals. Whether you're printing soft-hand water-based tees, high-opacity plastisol prints, or UV-cured industrial graphics, Chromaline has a solution designed to work for you—not against you. Shop Chromaline online or find your nearest Chromaline distributor.
Need help choosing the best emulsion for your setup? Contact Chromaline's technical team for more information.