By Cassandra Balentine
Direct to garment (DTG) and direct to film (DTF) printers operate with bulk or cartridge ink delivery systems.
The best option for your organization comes down to volume, maintenance capacity, and business model, according to Marc Vila, director of marketing, ColDesi, Inc.
The choice is largely dependent on production volume and specific customer requirements. “Bulk ink systems are best suited for high-volume production environments, offering lower cost per print and reduced downtime due to fewer ink changes. Cartridge-based systems, on the other hand, typically have a lower initial investment and are well suited for lower volume or entry-level operations; however, they require more frequent cartridge replacements, which can increase ongoing operational costs and interrupt production,” offers Gabriel Crumpler, TA segment specialist, Mimaki USA, Inc.
Above: Mimaki offers various devices used in the production of customized goods.
Compare and Contrast
When it comes to selecting an ink delivery system for DTG or DTF, Timothy Check, senior product manager, Professional Imaging, Epson America, Inc., points out that it’s not a simple “either/or” choice. It really comes down to how the printer is used on a day-to-day basis.
“Vendors need to consider both production and quality needs when choosing between a cartridge or bulk ink system,” suggests Mike Davis, application specialist, Roland DGA Corp.
In general, Vila feels that if you’re running a high-output shop, bulk ink makes sense. This will have a lower cost per print and fewer refills. If you’re printing at a smaller to medium scale, cartridges are cleaner, easier, and more reliable with less babysitting. “It’s not about which system is ‘better,’ it’s about what fits your workflow.”
Taylor Landesman, VP, Lawson Workhorse Group, says the printer’s engineering/structure dictates the ink delivery system and whether it uses proprietary RFID-chipped cartridges versus bulk tanks.
The decision should account for a vendor’s primary operational priority and their ability to commit to rigorous, daily maintenance. “Cartridges are the best choice for beginners, high-mix/low-volume shops, or any shop where labor dedicated to maintenance is expensive or unreliable,” suggests Ayden Tran, digital marketing manager, Ricoh DTG. “Choose bulk if prioritizing lowest consumables cost per print above all else, a very high daily print volume that uses ink quickly, and a dedicated, highly-trained technician performing daily, time-intensive maintenance.”
The choice between bulk and cartridge inks largely depends on a print provider’s level of experience and where they are in their production journey, according to Scott Donovan, North America commercial leader, DuPont Artistri.
“For companies new to DTG or DTF, cartridge-based systems can be the easiest way to learn the process and get up and running quickly. As printers become more knowledgeable and confident, they may choose to convert an existing system to bulk ink or invest in a new one to gain greater flexibility and cost control,” adds Donovan.
Considering Cartridges
Several advantages are associated with cartridge-based ink delivery systems for DTG and DTF.
Generally speaking, cartridge-based systems provide more consistency for a printer, as the inks packaged in cartridges are manufactured to high standards, notes Davis.
Additionally, cartridges operate in a closed-loop system. “The closed-loop nature of cartridges eliminates the risk of introducing dust or debris into the lines during the refilling process, which is a common cause of nozzle deflection,” offers Landesman.
Cartridge systems shine when it comes to simplicity and consistency. “Because the ink is sealed and degassed issues such as micro bubbles that can lead to nozzle loss are avoided. Cartridges are also clean and easy to replace—no mess, no fuss,” explains Check.
Because cartridges are typically vacuum sealed, Landesman says this protects ink from oxidization and evaporation. “This is critical for white ink, which is prone to sedimentation and viscosity changes when exposed to air.”
“Less exposure to air means fewer clogs,” asserts Tran.
Cartridges typically incorporate internal filtration, degassing control, and controlled agitation, which helps preserve ink integrity and minimizes the introduction of contaminants into the printer. “This reduces the frequency of manual intervention, stabilizes nozzle performance, and lowers the overall maintenance burden,” offers Adam Tipre, owner, PrinterBiz, a DTG Connection Company.
Additionally, integrated RFID chips provide high-accuracy ink tracking and prevent the accidental mixing of incompatible ink batches or expired fluids, notes Landesman.
“One major advantage is having a single point of contact for support, since the printer, ink, and consumables are all part of the same eco-system,” notes Donovan.
Overall, cartridges offer plug-and-play convenience, reduced chances for user error and contamination, as well as lower maintenance. Vila feels these systems are well suited for small- to mid-size shops.
There are downsides to cartridge systems to consider.
First is cost. Tran suggests that cartridges tend to carry a higher cost per milliliter compared to bulk ink.
This increased expense is “due to the additional engineering and packaging involved,” agrees Check.
Davis adds that cartridges need to be replaced more often than bulk ink refills.
Cartridge-based systems have limited ink capacity, making them less practical for long or continuous production runs. “Additionally, as business grows and print volumes increase, cartridge systems become less efficient to scale and can be less cost effective compared to bulk ink systems,” admits Crumpler.
Inventory overhead can also be a disadvantage. “Managing a fleet of small cartridges requires more storage organization and more frequent procurement cycles compared to stocking a few five-liter jugs,” shares Landesman.
“While cartridge systems may carry a higher nominal ink cost, many vendors find that the reduction in downtime, maintenance labor, and wasted ink and media offsets the price difference. In high-reliability or low-maintenance environments, cartridges often deliver a lower total cost of ownership and more predictable production output,” adds Tipre.
Bulk Pros and Cons
Bulk systems also bring benefits for DTG and DTF.
Landesman points to three main advantages of bulk ink delivery systems—lowered operating costs, reduction of single-use plastics, and refilling abilities.
“Bulk ink is more economical, often reducing the cost per milliliter by 60 to 80 percent compared to cartridges. This is the biggest factor in achieving a rapid return on investment,” says Landesman.
Landesman adds that bulk systems allow for “on-the-fly” refilling. In some configurations, ensuring that a high-capacity run isn’t interrupted by an “ink out” error mid-print. It also eliminates any RFID chip reading/resetting errors.
Davis agrees, confirming that an advantage of bulk ink systems is that they require fewer refills than cartridges.
Check believes that bulk ink systems are all about flexibility and cost savings. “They allow users to have an abundance of ink on hand, generally at a reduced cost since the users are not paying for the materials required to manufacture individual cartridges or the microchips included.”
Vila notes that the lower cost per milliliter afforded by bulk ink delivery systems is ideal for production-heavy businesses because it’s easier to scale with bigger runs.
Since bulk systems deliver a lower cost per liter, this also reduces operating expenses for higher volume or more experienced print providers, adds Donovan.
The downsides to bulk systems involve maintenance considerations.
“High exposure to air/humidity leads to faster degradation, pigment crystallization, and potential clogging issues,” cautions Tran.
“You do not want to have too much on your shelf as it can settle and/or separate,” says Landesman.
“You need a team that stays on top of cleaning if you’re not printing consistently. Bulk ink can clog easier and cost you downtime. Users must be diligent about storage and refill standards,” warns Vila.
Maintenance includes monitoring and manual daily intervention—stirring, cleaning, filling—to prevent pigment separation and clogs, notes Tran.
Bulk ink relies on open or semi-open refill processes, which increase the risk of airborne contamination, particulate ingress, and moisture exposure. “Even microscopic contaminants can disrupt ink flow, interfere with dampers and filters, and accelerate nozzle deflection or clogging—particularly in white ink systems where pigment density is higher. This results in more frequent clean cycles, elevated ink consumption during maintenance, and increased wear on printheads,” explains Tipre.
Bulk systems place greater emphasis on operator consistency and environmental control. “Variations in refill technique, agitation methods, storage conditions, and temperature stability can introduce inconsistencies in ink viscosity and pigment suspension. Over time, this can lead to uneven print density, color shift, and premature component failure,” adds Tipre.
Vendors should evaluate the entire ink delivery ecosystem. “While bulk and refillable cartridge systems can appear attractive from a cost standpoint, they introduce variables that can negatively impact print stability, maintenance requirements, and overall operating efficiency,” suggests Tipre.
Bulk systems are not ideal for low or inconsistent production volumes, as ink may remain in the lines too long, expire, or require frequent purging when the printer is idle. “Bulk ink systems carry a higher risk when issues occur, since problems such as contamination or system failure can affect a larger volume of ink,” offers Crumpler.
Bulk systems present upfront savings, but they place responsibility on the user. “Maintenance requirements are typically higher, warranties on ink-related components are often limited, and changing ink suppliers often means re-profiling materials to keep colors consistent,” shares Check.
Decisions, Decisions
There are options for both DTG and DTF ink delivery systems.
“The choice between bulk and cartridge ink delivery systems should be driven by production volume, operator skill level, environmental controls, and tolerance for maintenance,” concludes Tipre.
Mar2026, Digital Output
