Polyester Ink & Dyno Base Charges

Technical Explanation for Broker Partners

We have been asked multiple times this year about the “Poly” and “Dyno” notations that appear next to the color count on invoices. This has understandably caused some confusion, particularly when reviewing invoices and noticing that a job is marked “Poly” or “Dyno” and questioning why it was applied.

At this point, I believe it is important to clearly explain our position and perspective on these charges. I apologize in advance for the length of this explanation, but there is no short way to properly explain this subject without leaving important details out.

Understanding Polyester Ink Charges & Dyno Base Charges

To properly understand these charges, you must first understand what polyester ink and Dyno base are, and why they are necessary.

Polyester Fuming (Dye Migration)

Polyester garments release a gas during the curing process (when the garment passes through the dryer/oven). This gas is commonly referred to as “fuming” or dye migration. If not properly blocked, this gas can migrate into the printed ink layer and alter the color of the design after production.

This does not always happen immediately. A design can come out of the dryer perfectly printed — for example, a bright orange — and within a few days, after the customer opens the box, that same orange may have turned into a dark, muddy green.

Similarly:

A perfectly white print on a red polyester shirt can turn pink.
Dark colors are especially vulnerable.
The higher the polyester content, the higher the risk.

The more polyester content in the garment, the more severe the dye migration risk becomes.

When Polyester Ink Is Required

If a garment contains any polyester blend (for example, 10% polyester/ 90% cotton), fuming may occur. In these cases, a polyester white ink is sufficient. Polyester white ink has enough blocking capability to prevent low levels of dye migration.

However, when polyester content increases, so does the risk. At 100% polyester, a much stronger barrier system is required — this is where Dyno base becomes necessary.

Vendor vs. Aftermarket Garments

Garments from major wholesale vendors such as:

SanMar
S&S Activewear
Staton

are generally tested and known to release minimal dye migration when properly cured.

However, aftermarket garments (non-wholesale vendor sourced) have not been tested to the same standard. We refer to these as “aftermarket” products. Printing on aftermarket polyester materials carries significantly higher risk.

It is a risky procedure using polyester materials that are not sourced from established vendor wholesalers.

Polyester Ink Charge (Specialty Ink / Process Charge)

The polyester ink charge is listed on the price sheet under the Specialty Ink / Process Charges section (the smaller chart beneath the primary pricing chart).

This charge exists to cover the actual cost difference between standard ink and polyester-specific ink.

For example:

5-gallon bucket of regular white ink: approximately $150–$175
5-gallon bucket of polyester white ink: approximately $450–$500

This is a significant cost difference. The polyester ink charge exists strictly to offset that material cost increase.

Important Policy Note

The polyester ink charge is not always shown at proof stage.

Our graphic artists may not always know:

The exact garment type being used
Whether there is a polyester blend
Whether a substitution was made

Per broker guidelines:

If the garment contains any polyester, a polyester ink charge will apply.
It is the broker’s responsibility to know the garment composition at the time of ordering.
We reserve the right to apply the polyester charge without re-proofing when applicable.

What Is Dyno Base?

Dyno base is a grey barrier ink layer (also referred to as a barrier base).

It is printed between the garment and the design to prevent dye migration. It is not visible in the final printed image.

Dyno is required in the following situations:

100% polyester garments
Garments that are 51% polyester or greater
Aftermarket products
Any material our production team identifies as high-risk for dye migration

In some cases, garments marketed as “cotton” are actually synthetic variations that behave like polyester during curing.

Example:
The Bella + Canvas Sponge Hoodie line has shown dye migration characteristics despite cotton marketing claims.

We often do not know there is an issue until production. Only experienced press operators can sometimes identify materials that have a higher chance of fuming.

If the material is unusual, synthetic, or questionable, Dyno will most likely be used as a preventive measure.

Here is a link to our infographics to explain it better: https://j6broker.com/wp-content/uploads/2024/02/Poly-Printing-Infographic_BROKER.pdf

Why Dyno Has Two Charges

Dyno technically creates two cost factors:

It counts as an additional print color.
It is a specialty ink beyond standard cost.

Therefore:

It increases the color count.
It includes a specialty ink surcharge.

When Will Dyno Be Charged?

The main question we receive is:

“When will we know if we are being charged for Dyno?”

The answer is simple:

We always charge according to the approved proof.

We do not upsell Dyno unless it is reflected on the approved proof.

Broker Guidance for Pricing Your Customer

For planning purposes:

If the garment is not 100% cotton → expect a polyester ink charge.
If polyester content is 51% or higher → expect Dyno base.
If the garment is aftermarket or unusual material → expect Dyno base.

If Dyno is not charged on the invoice, consider it additional profitability or savings.

Production Priority: Print Quality Over Profitability

Our graphic team makes every effort to identify Dyno-required jobs at proof stage. However, there are occasions when it is missed.

Production has been instructed clearly:

Print quality takes priority over job profitability.

If production determines Dyno is necessary, they will use it.

There is nothing worse than delivering a perfectly printed job that later experiences dye migration and ruins the order.

Real-World Example

Example job:

Navy shirts
Proofed as:
3-color front / 3-color back
White base, Red, White highlight

Because the garment was not 100% cotton, a polyester charge was expected.

When production opened the box, they determined it was 100% polyester and required Dyno.

They printed:

Dyno base
White base
Red
White highlight

Technically printing it as a 4/4 job.

You are invoiced as:

3/3 DYNO (per approved proof)

We absorb the additional color count in this scenario as a courtesy.

Since Dyno and Polyester carry the same pricing structure, we list “DYNO” to indicate the barrier was used. The cost remains aligned with agreed pricing.

Polyester & Dyno Relationship

Any job requiring Dyno base will also utilize polyester ink for white base and highlights.

At this time, we are not double charging for both Dyno and Polyester unless explicitly communicated prior to production.

Large Order Exception Policy

We reserve the right to re-proof if a job presents extreme cost exposure.

Example:

3,000 piece order
No Dyno reflected at proof stage
Garment arrives and is 100% polyester

We cannot absorb a loss of that scale.

In that situation:

We will contact you
We will re-proof with Dyno reflected
We will wait for approval before printing

If we print first, we will not retroactively request additional charges.

We also reserve the right to correct future reorders if Dyno was missed previously.

Always review your proof carefully.
In our industry, the approved proof is the final authority.

Position Charges Clarification

The Polyester / Dyno specialty charge is applied once per order.

It is not multiplied by number of print locations.

Example:
2-color front
2-color back
2-color sleeve

Poly/Dyno charge is applied once — not per location.

Future Updates

This page will serve as the official reference for Polyester and Dyno policies for J6 Broker partners.

Information will be updated as material costs, vendor standards, and production data evolve.

If material costs significantly increase, adjustments will be reflected in future price list updates.

At this time, we aim to maintain competitive pricing while ensuring long-term print integrity and quality control.