Setup Showdown: Manual vs ROQ PRU vs Laser to Screen (LTS)

When it comes to getting your designs on press efficiently and accurately, the screen setup process can make or break your print workflow–understanding how different setup methods affect your time and precision is key. In our latest video, we compared three registration techniques: manual setup, ROQ’s PRU (Positive Registration Unit), and the SAATI Laser to Screen (LTS) system.

Each setup method was used in a four-screen shop configuration: underbase white, bright green, light green, and highlight white. This screen count reflects a typical spot color design with a white base, two distinct greens for depth and vibrancy, and a final pop highlight in white.

In the video, you’ll notice that our technicians, who don’t screen print every day took a casual, un-rushed pace through each process. This makes the time comparisons even more meaningful, showing real-world performance rather than idealized lab conditions.

Let’s look at time per screen for each method:

LTS (Laser to Screen): The fastest by far, finishing all four screens in just 10:33, or approximately 2 minutes and 38 seconds per screen. Since the artwork is digitally burned with perfect registration, almost no adjustments are needed on press.

ROQ PRU + SRP: With a total time of 17:14, the per-screen time drops to about 4 minutes and 18 seconds. The templated film placement really cuts down the time spent aligning on press.

Manual Setup: At 22:20 total for four screens, that’s roughly 5 minutes and 35 seconds per screen. Most of this time came from careful alignment and repeated micro-adjustments on press.

Let’s break it down.

Manual Setup: The Tried-and-True, But Time-Heavy Method

In this traditional approach, Mike shows us how to register screens by hand using a center line and a trusty T-square.

The process:

1. Measure the screen manually (in this case, 23x31).

2. Mark the center at 11 ¾ inches.

3. Use the T-square and visual registration marks to place your film.

4. Tape all four corners.

5. Adjust alignment directly on press, micro-adjusting with each screen.

Takeaway:

Manual setup definitely works—but it’s time-consuming and highly dependent on the operator's precision. Even with a seasoned vet like Mike, it required several micro-adjustments to get things dialed in. This method is great for learning the fundamentals, but not ideal for speed or scalability.

Setup Time: 22:20

ROQ's PRU (Positive Registration Unit): A Major Step Up in Speed

Next, we used the ROQ PRU along with a special registration pallet (SRP), which drastically reduces setup time by templating your artwork placement.

The process:

1. Place films using the PRU and template system.

2. Tape the film onto the screens once registered.

3. Expose screens and dry them.

4. On press, use the SRP to line up all screens quickly.

5. Minimal micro-adjustments needed.

Setup Time: 17:14

Takeaway:

The PRU cuts down setup time significantly compared to manual, with far fewer adjustments required. This makes it an ideal middle-ground solution for shops that want improved speed and accuracy without jumping all the way into LTS territory.

LTS (Laser to Screen): Precision and Speed at the Highest Level

Finally, we looked at the SAATI LTS—a fully digital imaging solution that automates artwork placement directly onto screens.

The process:

1. Drag and drop artwork into the RIP station.

2. LTS auto-rips and sends files to the production folder.

3. Load screens into the unit, which uses three points of contact to lock everything in.

4. Done and ready for press.

Setup Time: 10:33

Takeaway:

LTS removes the human error factor almost entirely. With three-point registration and automation, it offers the fastest and most precise setup, hands down. Of course, there's a price tag to match, but if you're printing high volumes daily, the ROI is hard to beat.

Every method will get the job done—it’s just a matter of how fast and how precisely. Here’s a quick recap:

Method	Setup Speed	Accuracy	Ideal For
Manual	Slow	Moderate	Small shops, beginners
PRU + SRP	Fast	High	Mid-size shops, growing businesses
LTS	Fastest	Ultra-precise	High-volume, high-efficiency shops

So—how long do you want to take? Whether you’re just getting started or looking to streamline your production, these tools give you options to match your workflow and goals.

Want to see it live?

Reach out to us ROQ.US, or follow us on social media to set up a demo. Come by, try it out, and let’s dial in your setup process together!