The short answer: what matters in a process combination is sequence and curing compatibility, not how many steps you stack. Decide the main visual first, whether that is a large base coat area or the primary pattern, then place the supporting processes: accents, identification marks and metallic finishes. Check that the curing conditions of each step will not damage the effect of the step before it. Every extra process adds cost, risk and lead time, so use as few as the design allows.
1. The eight processes, laid out
| Process | What it delivers | Line |
|---|---|---|
| Screen printing | rich colour, sharp small text, multi-colour registration | in-house line |
| Hot stamping | metallic finish in a single pass | in-house line |
| High-temperature firing | pattern bonds firmly, resists rubbing and washing | in-house line |
| High-temperature glazing | glazed surface, high value added | in-house line |
| Decals | carries complex artwork and many colours | in-house line |
| Raised embossing | three-dimensional feel | in-house line |
| Plastic cap printing | screen printing on PP and ABS caps, scratch resistant | in-house line |
| Spray coating | overall colour change, matte or gloss | outsourced processing |
Of these eight, the first seven run on in-house lines. Spray coating is outsourced processing and is not completed inside our own plant. One further item is often mistaken for a decorative process: the pre-print flame treatment section in the automatic machine shop. It improves the state of the glass surface and the adhesion of the ink, which makes it a pre-print step, not a decorative process that can be delivered on its own, so it is not counted among the eight above.
2. Three common combinations and where they fit
| Combination | Effect | Suited to | Watch out for |
|---|---|---|---|
| Screen printing + hot stamping | base coat plus metallic marks, clear hierarchy | branded bottles, prominent logo | the hot stamping must sit over the base coat; the order cannot be reversed |
| Decals + hot stamping | complex artwork plus small metallic accents | gift lines, intricate designs | stamp after the decal has cured, so the decal is not damaged |
| Screen printing + high-temperature firing | pattern bonds firmly, resists rubbing and washing | export, daily use, durability first | firing occupies the tunnel kiln section |
If the design needs the whole bottle recoloured first, that is spray coating: an outsourced step that must be scheduled separately. Any combination involving spray coating plus screen printing has to be flagged in advance, so the processor can coordinate the overall schedule and quality control.
3. The rules for sequence
- Large areas first, accents last: apply the broad base coat first and layer the small metallic or special-effect areas on at the end.
- Heat-resistant steps before low-temperature ones: processes that pass through the tunnel kiln generally come first, so that high temperature does not destroy an effect that has already been formed.
- Confirm compatibility first: whether the inks, hot stamping foil and decal paper of two processes react with each other once layered must be verified by sampling.
- Cut combinations that add nothing: two processes whose results cannot be told apart just cost money and add another risk.
4. Cost and risk of adding processes
Each additional process means another load and unload, another positioning step and another curing pass. The more layers you add, the more the losses accumulate and the longer the lead time. A combination is therefore a trade-off: what you pay for differentiation is not only the unit price but also less certainty on lead time and a higher risk of rejects.
This is where it pays to have several processes under one roof: you do not have to pass bottle blanks back and forth between suppliers, reconcile lead times or argue over who is responsible. Our in-house processes cover the seven categories above, and the bottle and its PP or ABS plastic cap can be finished together, so you do not need a second supplier for cap printing. Only spray coating is outsourced.
5. How to get your supplier to map the route for you
Give all of the following in one go, and your supplier can propose a combination that can actually be executed:
- A photo or drawing of the bottle shape, and whether stocked bottle blanks exist for it.
- A target artwork reference marking which areas need a metallic finish and which need a three-dimensional feel.
- Colour requirements (Pantone codes).
- Quantity and lead time.
Our sampling lead time is 1-3 days and enquiries are answered the same day. Ask your supplier for a process route proposal that sets out the sequence, the success rate, the risk points and the price together, and only then decide whether to stack everything. With complex effects, the question is never how many steps are possible but whether one step can hand over to the next reliably.