Fabric Printing Techniques

TEXTILE PRINTING

APPLICATION OF COLOR T O

FABRIC I N A

DESIGN OR PATTERN

OBJECTIVES
1. G O O D REGISTRATION
2.
3.

G O O D CLARITY

G O O D DEFINITION
G O O D PENETRATION

4.

5.
6.

G O O D FASTNESS
LOW PERCENTAGE SECONDS

TYPES OF PRINTING PROCESSES

I.

AUTOMATIC FLAT SCREEN PRINTING

A.

APPROXIMATELY 17% OF PRINTED GOODS

B.

'

ADVANTAGES

(1)

LARGE REPEATS

MULTIPLE STROKES FOR PILE FABRICS

C.

DISADVANTAGES

SLOW

N O CONTINUOUS PATTERNS

I1 ,

ROTARY SCREEN PRINTING

A,

APPROXIMATELY

&% OF

PRINTED GOODS

B.

ADVANTAGES

(2)

QUICK CHANGEOVER OF PATTERNS

(3)

CONTINUOUS PATTERNS

C.

DISADVANTAGES

(1)

DESIGN LIMITATIONS

(2)

SMALL REPEATS

111.

ENGRAVED ROLLER PRINTING

A.

APPROXIMATELY 26% OF PRINTED GOODS

B.

ADVANTAGES

(1.)

HIGH DESIGN CAPABILITY

A.

FINE DETAIL

B.

MULTIPLE TONES

C.

DISADVANTAGES

(1)

COPPER CYLINDERS VERY EXPENSIVE

(2)
--

NOT ECONOMICAL FOR SHORT RUNS

(3)

REQUIRES HIGHLY SKILLED WORKERS

IV.

HEAT TRANSFER PRINTING

A.

APPROXIMATELY 7% OF PRINTED GOODS

B.

ADVANTAGES

(1)

HIGH QUALITY PRINTS

(2)

FEWER SECONDS

(3)

ECONOMICAL FOR SHORT RUNS

(4)

PRACTICALLY POLLUTION FREE

C.

DISADVANTAGES

(1)
--

SLOW

(2)

PRIMARILY ONLY FOR POLYESTER

STEPS I N PRINTING PROCESS

1. P R E P A R A T I O N O F P R I N T P A S T E

2. P R I N T I N GO F F A B R I C
3. D R Y I N G 4. F I X A T I O N O F D Y E S T U F F

5. W A S H I N G - O F F

Preparation of printing
~ y p e specific farmulation used d e p e d s on of

fiber, the mlarant -tan

u s d and, to

extent, the

dyes ar Pi birrlers, cross-linking agents

m i n g agents surfactants bater-retaining agents (-ants) a3kSirm prcrrptess

&f-tal*

--

handnodifiers

--

viscosity

resistthidmss of t h f l u i d )

of a fluid to f l o w

(ie. t.b

print paste

- faxmula-

a m of t h IIDst impartant variables i a n

can be c ml d by choosing from a w i d e m le range of possible t h k h r x x products, nrsaifif2dby i tarperature, pH, arrl electrolyte n

wians

- (oil-in-water, w a t e r - i n - i l )

of Print P a s t e s

E f f e c t of Eledm3ly-5

Effect of cancentration

THICKFNING AGENTS MUST

H A V E P S E U D O P L A S T I C FLOW B E H A V I O R

Low S H E A R = H I G H V I S C O S I T Y

H I G H S H E A R = Low V I S C O S I T Y

SHEAR RATE
PSEUDOPLASTIC B E H A V I O R

THICKENING M E D I A
S O L U T I O N SO F P O L Y S A C C H A R I D E S - GUM ARABIC - GUM TRAGACANTH

- LOCUST BEAN GUM - GUAR GUM - SODIUM ALGINATE

EMULSIONS
-.

0 I L - I WATER
O I L IS U S U A L L Y V A R S O L

- WATER-IN-OIL

SYNTHETIC (ALL-AQUEOUS) - POLYACRYLIC ACID -EMA R E S I N G ELECTROLYTE S E N S I T I V E

FOAMS

- AIR

DISPERSED I N WATER

11

capable of fauning a

ionalfilmusedto

inpartant in d e t e g

fastrvpss

a l l y

syntbtic (lata)c~llpounds

--

12

calgm

- often

used to soften e t e r

Surfactats

- used to

-particles,

into the fiher,

S i m i l a r in 135e are protective colloids

increasing paste stability,

Smfactants

can be

scatianic
S+
S

Hurectants

mi l -as

aWed t o print paste fmtrdatians to

print paste formulations to prevent e e r evaparatim

the paste
instability

- preventing

-kn' si-

ard paste

,Increaseadhesion of b i d e r systan to substrate

Le,

Pi-t

printing of fiberglass isenhanoed

by using aninffi-

--

Added to print pastes to " i z e

f m t i m of

foan (before foan printing).

often
any

SiJiaXE

surfactants have been d which

bubble fanmtirm

in t b print paste a d - t is
be usfa.

no

effects can

Catalysts

A c f i e m i c a l dded t o a fanrailation t o
speed of a c h m k a l . reaction,

be in!Clu3f?d print paste in

fcurrplLation

far

AUXILIARY CHEMICALS

THOSE

N E C E S S A R Y F O R F I X A T I O N OF D Y E O N T O F I B E R

REACTIVES VATS

ALKALI

- REDUCING AGENT

ACLDS - ACID

CATIONIC- A C ~ D

DISPERSE - CARRIER
DO N O T I N C O R P O R A T E S T R O N G A C I D , B A S E S , O X I D I Z I N G A N D R E D U C I N G
AGENTS IN PRINT PASTE.

ACID AGER LATENT R E D U C I N G AGENTS ( S O D I U M S U L F ~ X Y L A T FEO R M A L D E H Y D E )

SCREEN ENGRAVING PROCESS

1. P R E P A R A T I O N O F P O S I T I V E F I L M
A. COLOR S E P A R A T I O N
.

. B. S T E P A N D R E P E A T
C.
REGISTRATION AND ACCURACY

2. T R A N S F E R T O S C R E E N
A.

LACQUER METHOD

5. G A L V A N O METHOD

LACQUER METHOD

PERFORATED SCREEN PREFORMED

A. HEAT

B.
C.

DEGREASE A N D CLEAN COAT WITH LIGHT - SENSITIVE EMULSION DRY

E.

F I L M P L A C E D IN C O N T A C T W I T H SCREEN EXPOSE
WASH

F.

TO L I G H T

G.
H.

INSPECT

1.

CURE
INSTALL END RING

J.

FLAT-BED SCREEN

P R I N T I NG

M E C H A N I Z A T I O N O F H A N D SCREEN P R O C E S S -

F A B R I C G L U E D TO B L A N K E T
S C R E E N S R I S E AND F A L L P R I N T I N G DONE W H I L E SCREEN I N D O W N POSITION R O D O R BLADE SQUEEG.EE S Y S T E M

U P T O FO'UR S T R O K E S P O S S I B L E
SLOW PROCESS

i o .-

W LLI
(3

W W

z a

Q)

I
LL

R O T A R Y S C R E E N PRINT.ING

C O N T I N U O U S SCREEN P R I N T I N G PROCESS

F A B R I C GLUED TO B L A N K E T

F A B R I C MOVES UNDER R O T A T I N G SCREENS

R O D OR B L A D E SQUEEGEE S Y S T E M

FINE ADJUSTMENTS

EASILY MADE

S P E E D S U P TO 100 Y D J M I N .

--

-?A

5 0
LL

W
(3

W W

v ,

F I X A T I O N METHODS

1. A T M O S P H E R I C

STEAM

TREATMENT AT

212

DEGREES

WITH

SATURATED STEAM

USED

WITH

DIRECT DYES
VAT DYES
NAPHTHOL

DYES

ACID

DYES

DYESDYES

CATIONIC

REACTIVE

FESTOONSTEAMER MOST COMMON EQUIPMENT

ACID

AGER

FOR

ACID

DYES

2. PRESSURE STEAM

TREATMENT

AT

230

DEGREES

UNDER LON P g E S S U R E

USED WITH DISPERSE DYES

TURBO-AUTOCLAVE MOST

COMMON E Q U I P M E N T

3. H I G H TEMPERATURE STEAM

TREATMENT 420

WITH

SPUERHEATED STEAM

AT

TEMPERATURE UP

TO

DEGREES

USED

WITH

DiSPERSE

DYES

P IGMENTS

C A N A L S O B E U S E D As A N A T M O S P H E R I C

STEAMER

4. D R Y HEAT

TREATMENT
USED WITH

WITH

DRY HEAT

AT

TEMPERATURES

UP T O

420

DEGREES

DISPERSE
REACTIVE

DYES

DYES

P I GMENTS

R E A S O N S FOR S C O U R I N G R E M O V E THE T H I C K E N I N G . A G E N T REMOVE AUXILIARIES REMOVE EXCESS DYESTUFF I M P R O V E B R I L L I A N C E OF P R I N T I M P R O V E F A S T N E S S P R O P E R T I - E S OF PRINT

PROBLEMB A C K S T A I N I N G OF U N D Y E D A R E A S

PIGMENT P R I N T I N G
70%
OF ALL

P R I N T E D F A B R I C S I N U.S.

ARE

P R I N T E DW I T H P I G M E N T S

C O M P O S I T I O N OF P R I N T P A S T E

PIGMENT T H I C K E N E R (EMULSIONOR A L L . BINDER (ACRYLIC POLYMER) Low C R O C K B I N D E R SOFTENER

AQUEOUS)

PROCESS
1. P R I N T

2. D R Y 3. C A R E

ADVANTAGES - ALL F I B E R S AND F I B E R BLENDS - No A F T E R W A S H DISADVANTAGES - POOR CROCK FASTENESS -- HARSH HARD

Typical P i p t Print Ebmuhtion

8

nrywtxight
10%
3%
2%

1/108 5-10%

18
1/10%
1/28
2%

77%

DEFECTS I N SCREEN PRINTING

OUT OF REGISTRATION

LINT A N D IIIREALI MARKS GLUE STREAK

COLOR SMEAR
COLOR OUT

CREASED FABRIC

PINHOLE
--

DAMAGED SCREEN

c .C

Q,

a
I L

3 W 5:

Fabric i s first printed with a r e s i s t i n g agent, then dyed. Produces s i m i l a r effects t o discharge printing. Can use white or colored resists.
Can use dyes of much higher s t a b i l i t y than those used i n discharge

printing and, t h e r e f o r e , much higher f a s t n e s s can be obtained.

Discharge p r i n t i n g is a method where a "dyed" f a b r i c i s p r i n t e d with discharging agents M c h s e l e c t i v e l y d e s t r o y t h e dye. produced.

An a l t e r n a t i v e method is t o p r i n t along with discharging a g e n t s ,
A white d i s c h a r g e i s

nondischargeable dye wtrich g i v e s a colored discharge surrounded by a "ground"

color.

Advantages

1) Large areas of ground c o l o r p o s s i b l e

2)

Delicate c o l o r s and I n t r i c a t e p a t t e r n s p o s s i b l e on deep ground c o l o r

excellent depth and c l a r i t y possible

3)

Higher production c o s t s but long lasting, unique s t y l e s

--

HEAT TRANSFER PR INTI NG

Advantages

I. Easier handling of units 2. Easier training of operators 3. Better registration and clarity
4.
Fewer Seconds (2% vs. 10%)

5. 1 nventory in paper

6 Pollution .

- free

Disadvantages

1.
2

Slow
Limited to synthetic fibkrs mainly polyester

3
P
W 0 K

I! I n

a e

a
0

c p

s a

r,

PRESENT USES OF HEAT TRANSFER PR I NTS

Knitted Apparel Woven Apparel

Drapery Fabric

Upholstery Fabric Automobile Interiors Carpet Tiles

--

RECENT I NNOVATI ONS I N HEAT TRANSFER PR 1 NTl NG

Deep Penetrating Dyes for Pile Fabrics Cationic Dyes for Pr inti ng Acrylics
-

Processes for Printing PolyesterlCotton Blends

1. Coating Cotton Fiber with Polyester Resin. 2. Resin Fixing Dyes on Cotton.

Wet Heat Transfer Printing