Textile printing process part -1

Printing

Introduction:

In the apparel industry, besides the artwork to be printed, the most important thing is the printing technique. There are several printing techniques, and each of them is suitable for a certain business strategy. Printing can also be defined as localized dyeing. Defined as the application of dye or pigment in a different pattern on the fabric and by subsequent after treatment of fixing the dye or pigment to get a particular design. Being a designer you may have multiple options to decide which printing techniques is most suitable for a specific design on the garment. Experienced designers choose printing method primarily on the basis outcome as design sharpness, durability, brightness, texture and hand feel. Sometimes a printed fabric can be identified by looking at the backside of fabric where there is no design or color as face side. In cotton, dyes like vat, reactive are used. In manmade, dyes like disperse and cationic are used. As when a design comes for production, we need to consider many things to choose a particular printing method. It has an array of amenities with coupled of inconvenienced that I will elaborate detail with the help of this topic.

History

The earliest example of printing onto textiles dates back to the 4th Century B.C. The simple yet effective wood block printing method (which most likely originated in China) was used throughout East Asia and long before the technique was ever used to print on parchment or paper.

 

Patented by Thomas Bell in 1783, and first used in the Lancashire fabric mills, roller or machine printing began to produce printed cotton fabrics in the early 1790s.
Using a revolving engraved metal cylinder, the machine which could print one consistent color onto the fabric, was not only capable of mass production compared to traditional wood block printing but was also very cost effective compared to traditional techniques.
Then by 1860 and following a number of key enhancements, roller-printing machines could not only process expensive fabrics with delicate designs, but could also print up to eight colors simultaneously. However even with these developments in textile print technology, specialist woodblock printing, unlike traditional screen print which still exists today, was still needed to finish large scale soft furnishings, and wasn’t completely replaced by the commercial printing industry until the early stages of the 20th Century.

The introduction of digital machines

In the late 1980s, the industry made another leap in technology with the introduction of digital printing. Like its predecessor, the roller machine, this new type of machine began to revolutionize the industry. Using an ink-jet method to physically print color dyes onto textiles, the process was originally used to produce very small orders such as corporate wear and fabric communication items such as flags and marketing banners. Then in the early 1990s came the development of the sublimation printer.

Types of printing:

There are some printing method which are given below

1)      Flock printing 2) Rubber printing 3) Pigment printing 4) Digital printing 5) Screen printing

6) Puff printing 7) Burn out printing 8) Metallic printing 9) Transfer printing 10) Spray printing 11) Floral printing 12) Heat transfer printing

Importance of printing

1.      Printing is very much important to make new design/style.

2.      It helps to make the fabric /garments more attractive & lucrative.  

3.      To fulfill the customer requirement.

4.      It also helps to change the shape of the garments.

There are catalog number of reason so as to stand up in favor of this topic. At the very outset, Printing is plays pivotal rule in textile sector. With the help of this topic, we will get detail of some printing process as exemplified Rubber, Flock, pigment, Foil printing, Puff printing, Glitter printing etc.

 

Section: 80

Pigment Printing Process

                                              80.0 Purpose

                                              80.1 Scope

       80.2 Responsibility

                                              80.3 Definition

80.4 Procedure

80.4 Reference

Pigment Printing Process

80.0 Purpose:   

ü  Pigment print can be applied both natural as well as synthetic.

ü  This process produce maximum output of printing.

ü  Increase the color fastness.

80.1 Scope: This process is applicable for printing unit.

80.2 Responsibility: : Quality Control In‐charge, Manager Production, Color in master and Manager Store are responsible for ensuring that this procedure is followed during operation.

80.3 Definition: A substance in particulate from that is substantially insoluble in a medium but which can be mechanically dispersed in this medium to modify its color and light – scattering properties.

In other words, Pigments are insoluble coloring matter mostly mineral origin have been used for the coloration of metal wood, stone, and textile material.

80.4 Procedure: Pigment printing recipe are given below

 

 

Section: 81

Flow chart of Rubber Printing Process

Introduction of Rubber printing

The Rubber Printing System is the first ink jet printer in the world to successfully print with co-curable inks on uncured tire components and rubber products. This specialized printer fully automates the marking process, streamlining the production process and eliminating mistakes.

Section: 82

Flock Printing Process

82.0 Purpose

  82.1 Scope

          82.2 Responsibility

  82.3 Definition

   82.4 Procedure

  82.4 Reference

Flock Printing Process

82.0 Purpose:  Flocking is an article can be performed for the purpose of increasing its value in terms of the tactile sensation, color & appearance.

82.1 Scope: This process is applicable for printing unit.

82.2 Responsibility: Quality Control In‐charge, Manager Production, Color master and Manager Store are responsible for ensuring that this procedure is followed during operation

82.3 Definition: A process in which a fabric is printed with an adhesive, followed by the application of finely chopped fibers over the whole surface of the fabric by means of dusting-on, an air blast, or electrostatic attraction. The fibers adhere to the printed areas, and are removed from the unprinted areas by mechanical action.

82.4 Procedure: First a suitable adhesive is applied to the surface to be flocked .The flock is then applied, penetrate the surface of the adhesive to create the desire velvet finished.Electrostic flock applicator charge the flock particles which are then attached in grounded surface that is to be flocked .Unlikely puffer application method which merely sprinkle a flock layer into the surface. Electrostic ensure fibers that fabric all end up standing at right angle to the surface resulting in velvet finish. Electrostatic flocking is used extensible in the automotive industry for coating window rubbers, glove boxes, coin boxes, door cards, consoles, and dashboards. Rally cars usually have their dashes flocked to reduce reflections and to provide an as new finished to a modified dash. Flocking is proving successful in a number of artistic ventures including the decoration of jewelry, ceramics and pottery. Using suitable adhesives flock can be applied to an endless range of materials including plastic, metal, wood, rubber and fiberglass. Detailed Insight Consumers are always looking for something different and unusual. Suppliers seek the same thing - a special item or product that will increase their market share or generate new business. An example of this might be the recent popularity of mixed media garments in the marketplace. Adhesives that capture the fibers must have the same flexibility and resistance to wear as the substrate. The process uses special equipment that electrically charges the flock particles causing them to stand-up. The fibers are then propelled and anchored into the adhesive at right angles to the substrate. The application is both durable and permanent. Flock can be applied to glass, metal, plastic, paper or textiles. Flock design applications are also found on many items such as garments, greeting cards, trophies, promotional items, toys and book covers. Application Methods Decorative flocking is accomplished by using one of four application methods: electrostatic, beater bar/gravity, spraying and transfers. The electrostatic method is perhaps the most viable flocking method, especially for the printer doing more than an occasional flocking job. Flocking material can also be sprayed using an air compressor, reservoir, and spray gun similar to spraying paint. The resulting finish using this method is similar to a thin felt coating, as most of the fibers will be lying down in the adhesive. It is primarily used when large areas require flocking. It is an untidy process, because some of the flocking fibers become airborne. Flocking is also applied by printing an adhesive on to a substrate, and then rapidly vibrating the substrate mechanically, while the flock fibers are dispensed over the surface.

Flock application with the use of beater bars to help increase the density of the coating.

 
 Flock Fibers Flock can be made from natural or synthetic materials such as cotton, rayon, nylon and polyester. There are two types of flock - milled and cut. Milled flock is produced from cotton or synthetic textile waste material. Because of the manufacturing process, milled flock is not uniform in length, and can vary from fine (0~ - 0.5 mm) to coarse (0.4 - 1.1 mm). Cut flock is produced only from monofilament synthetic materials. The cutting process produces a very uniform length of flock. Lengths can be obtained from 0.3 - 5.0 mm and 1.7-22 dtex in diameter.