How many times did you reclaim the ones that failed?
I'm not printing custom jobs for other people, so I'm not frequently reclaiming screens. At most maybe I have reclaimed some of them 6 times. Never had one fail. Most places reclaim quite frequently, and I believe the limiting factor is when the mesh loses tension from use, not damage from reclaiming.
The emulsion remover should be doing most of the work. If your used screens are resistant to emulsion remover, then maybe the emulsion was not fully cured in the first place. In that scenario, the emulsion can react with inks and cleaners and become more or less permanently bonded to the mesh. Emulsion applied too thick and not dried all the way through is prone to this outcome.
It certainly will vary, according to a lot of factors, but I would estimate that we can reclaim and reuse screens in excess of 100 times. Of course, we are using re-tensionable screens so they get tightened every 40-50 uses.
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