MODERN & ENVIRONMENT PRINTING

Printing is another part of wet processing technology. Printing is carried out after
pre-treatment of fabric or after dyeing of the fabric. Printing is carried out for producing
attractive designs on fabric or other materials. The printing is described as localized
dyeing i.e., dyes or pigments are applied locally or discontinuously to produce the
various attractive designs on fabric. The main objectives of printing are the production of
attractive designs with well-defined boundaries made by the artistic arrangement of a
motif or motifs in one or more colors. Printed fabrics are well protected from friction and
washing if dyes or pigments are applied properly on fiber. A strong bonding is formed
between dyes and fiber.

Steps in Textile Printing: Textile printing is carried out in different steps, such as:

 At first, fabrics should be pre-treated before printing.

 Printing paste must be prepared by using printing ingredients; printing performance
depends on a well printing paste.
 Then, making an impression of the print paste on the fabric by using any of the printing
methods, which is required.
 After that, drying is carried out on printed fabric.
 Steaming is carried out on printed fabric for fixing the printing paste on the fabric.
 At last, printing fabrics are neutralized by the after-treatment process.

Styles of Printing: There are three different styles of printing. Such as:

1. Direct style of printing

2. Discharge style of printing.

 White discharge
 Color discharge

3. Resist style of printing:

 White resist
 Color resist

Methods of Printing: Printing is carried out with different instruments. Different

methods are used to produce impression on fabric. Methods of printing differ on the
demand of user. Also it depends on the materials type and type of purpose of end
product use. The following methods can be applied for textile printing operation. They
are as follows:

1. Block Printing
2. Burn-out Printing
3. Blotch Printing
4. Digital printing
5. Duplex Printing
6. Engraved Roller Printing
7. Electrostatic Printing
8. Flock Printing
9. Ink-jet Printing
10. Jet Spray Printing
11. Photo Printing
12. Rotary Screen Printing
13. Screen Printing (Flat Screen)
14. Stencil Printing
15. Spray Printing
16. Transfer Printing
17. Warp Printing
18. Special Methods (Tie dyeing and Batik Printing)

At the initial stage of printing, this printing work was done by hand but day by day this
style is changing by utilizing different modern techniques. Now different types of critical
printing is done very easily by the bless of modern science. Most of the printing
machines are controlled by the computer. Graphics design is mostly use in printing
process. Different types of textile machine manufacturing companies trying to improve
the present techniques of printing methods.

Anyhow, printing process plays an important role in the civilized world. Multiple colors
can be use in printing process. Sometimes printing properties show the identity of a
nation. So, we should give great emphasis on printing process to produce different
types of attractive design on textile materials.

Major printing process :

 Relief printing process

 Intaglio printing process
 Offset printing process
 Screen printing process

Relief printing process :

Relief printing is a family of printing methods where a printing block, plate or matrix that has
had ink applied to its surface, but not to any recessed areas, is brought into contact with paper. The
areas of the printing plate with ink will leave ink on the paper, whereas the recessed areas of the
printing plate will leave the paper ink-free. A printing press may not be needed, as the back of the
paper can be rubbed or pressed by hand with a simple tool such as a brayer or roller.
 Fig : Relief print

Intaglio printing process :

Intaglio, in visual arts, one of the four major classes of print making
techniques, distinguished from the other three method
(relief printing, stenciling, and lithography) by the fact that the ink forming the
design is printed only from recessed areas of the plate. Among intaglio
techniques are engraving, etching, dry point, aquatint, and mezzotint.

Fig : Intaglio print

Offset printing process :
It is also the highest quality printing process in the industry. The process produces prints
with rich, smooth solids without the streaking found in lesser quality prints. Actual inks are
used, not toner. The look and feel of any offset product comes across as more professional.
Used for - business cards, letterhead, catalogs, books/booklets, business
forms, flyers, brochures, calendars, invitations and so much more.

Fig : Offset print

Screen printing process:

Screen printing is the process of pr essing ink through a stenciled mesh screen to
create a printed design. It’s a popular technique used in a whole range of different industries,
so even if you've never heard of the term before today, it’s likely that you’ve worn or used a
screen-printed product at some point without eve n realizing. The process is sometimes called
serigraphy or silk screen printing, but all of these names refer to the same basic method .
MODERN PRINTING PROCESS
 Digital Printing :
This printing method is becoming more and more popular because
of its high-quality outputs and speedy printing process. In digital printing,
there is no need for plates to be prepared. It also doesn’t need to go
through the setup process like offset printing does so it saves a lot of
energy and manpower too. In addition, there are less chemical and paper
waste in this method because the ink and toner doesn’t get absorb by the
paper but only remains in the surface.

There are two main technologies that rules the digital printing industry.
These are inkjet and xerography. Inkjet printers are most commonly used
on posters, signage and short printing runs for books while xerographic
printers, or laser printing are used on brochures, direct mail, short printing
runs of books and other documents. Digital Printing is a better choice for
short printing runs because it is a lot cheaper than offset printing.

The two major types of offset presses are sheet-fed and web. The main
difference between these two is that in sheet-fed, the paper is already cut
prior to printing while in web press, the paper is in a roll first and cut after
printing. Offset printing is used on almost any type of printing on paper—
brochures, posters, newspapers, magazines, etc.
Inkjet Printing Technology :

Inkjet printing is a type of computer printing that recreates a digital image by

propelling droplets of ink onto paper, plastic, or other substrates. Inkjet printers are the
most commonly used type of printer and range from small inexpensive consumer
models to expensive professional machines. Inkjet printing technology provides
possibilities for new design styles and workflows, short production runs, sustainable
printing environments, quick response time, and customization.

Main Characteristics of Inkjet

 Master-less printing: counter to the conventional printing systems the inkjet

technology doesn’t require a master or printing plate to carry the ink and deliver it to
the substrate. This make inkjet printing technology suitable for Variable data
printing (VDP) and Short runs printing as there is no fixed or initial cost for printing.
That’s why inkjet is the most implemented technology in transactional printing even
more than other digital printing technology like the Electrophotography printing in
which there is a variable master created with each copy of printing.
 Non-impact printing: one of inkjet technology unique characteristics that it doesn’t
require any contact to transfer the ink to substrate; this gives it the ability to print on
very wide range of substrates even the sensitive materials and also Thick rigid
materials. Like wood, ceramic, glass & eggs.

 Different types of inks: inkjet technology can be work with different types of inks;
each type of ink can print on many substrates (porous non porous) which is
reflected in wide range of applications that can be handled with inkjet technology.

Inkjet machines structure

Fig : Flatbed Inkjet printing machine

Inkjet printing applications :

1. Digital textile printing
2. Coding applications
3. Digital label printing
4. Home and office applications
5. Printed electronics
6. Ceramic printing
7. Wood printing
8. Glass printing
9. Poste & sign printing
10. Production paper printing
11. 3D printing

As showed in the next diagram, Inkjet technology can be classified to two main
categories: -

1. Continuous inkjet (CIJ)

2. Drop on demand ink jet (DOD).

Continuous inkjet :
The continuous inkjet (CIJ) method is used commercially for marking and coding
of products and packages. In CIJ technology, a high-pressure pump directs liquid ink
from a reservoir through a gun body and a microscopic nozzle, creating a continuous
stream of ink droplets via the Plateau-Rayleigh instability. A piezoelectric crystal creates
an acoustic wave as it vibrates within the gun body and causes the stream of liquid to
break into droplets at regular intervals: 64,000 to 165,000 droplets per second may be
achieved. The ink droplets are subjected to an electrostatic field created by a charging
electrode as they form; the field varies according to the degree of drop deflection
desired. This results in a controlled, variable electrostatic charge on each droplet.
Charged droplets are separated by one or more uncharged "guard droplets" to minimize
electrostatic repulsion between neighboring droplets.
CIJ is one of the oldest ink jet technologies in use and is fairly mature. The major
advantages are the very high velocity (≈20 m/s) of the ink droplets, which allows for a
relatively long distance between print head and substrate, and the very high drop
ejection frequency, allowing for very high speed printing. Another advantage is freedom
from nozzle clogging as the jet is always in use, therefore allowing volatile solvents such
as ketones and alcohols to be employed, giving the ink the ability to "bite" into the
substrate and dry quickly. The ink system requires active solvent regulation to counter
solvent evaporation during the time of flight (time between nozzle ejection and gutter
recycling).
2. Drop-on-demand :
Drop-on-demand (DOD) is divided into thermal DOD and piezoelectric DOD.

Thermal DOD
Most consumer inkjet printers, including those from Canon (FINE Cartridge system), Hewlett-
Packard, and Lexmark, use the thermal inkjet process.
In the thermal inkjet process, the print cartridges consist of a series of tiny chambers, each
containing a heater, all of which are constructed by photolithography. To eject a droplet from each
chamber, a pulse of current is passed through the heating element causing a rapid vaporization of
the ink in the chamber and forming a bubble, which causes a large pressure increase, propelling a
droplet of ink onto the paper (hence Canon's trade name of Bubble Jet). The ink's surface tension,
as well as the condensation and resultant contraction of the vapor bubble, pulls a further charge of
ink into the chamber through a narrow channel attached to an ink reservoir. The inks involved are
usually water-based and use either pigments or dyes as the colorant. The inks must have a volatile
component to form the vapor bubble; otherwise droplet ejection cannot occur. As no special
materials are required, the print head is generally cheaper to produce than in other inkjet
technologies.
 Flexography
Flexography is a modern version of letterpress printing. This traditional method of
printing can be used on almost any type of substrate, including corrugated cardboard,
cellophane, plastic, label stock, fabric, and metallic film. The flexographic printing
process uses quick-drying, semiliquid inks. In this age of digital printing, flexography
holds its own in the areas of large orders and long print runs, particularly of packaging
products and labeling.

The printing method uses flexible relief plates that can be stuck to a printing cylinder. It
is also called as an updated version of letterpress, which is known as the original
printing process way back in 15th century. Flexography can be used in the printing of
food packaging, plastic bags, gift wrap, wall covering, magazines, newspaper inserts,
etc.

Fig : Flexography printing process

 Gravure Printing
Just like offset printing, gravure printing is also a great choice for
printing high quality and high volume materials like magazines, mail order
catalogues, brochures and other long run publications. This high-quality
printing technique utilizes direct contact between paper and an etched
 copper plate and can be very expensive. Gift wrap, wallpaper, plastic
laminates, printed upholstery, and vinyl flooring can also be created using
this printing process.

Gravure printing also has a sheet-fed process which is used for smaller
print runs. Examples of these items are artworks and prints, photographic
books, high quantity postage stamps, and some promotional pieces.

Fig : Gravure Printing Cylinder

 Modern Screen Printing

Screen printing is a printing technique whereby a mesh is used to transfer ink onto a
substrate, except in areas made impermeable to the ink by a blocking stencil. A blade or
squeegee is moved across the screen to fill the open mesh apertures with ink, and a reverse
stroke then causes the screen to touch the substrate momentarily along a line of contact.
This causes the ink to wet the substrate and be pulled out of the mesh apertures as the
screen springs back after the blade has passed. One color is printed at a time, so several
screens can be used to produce a multicolored image or design.
There are various terms used for what is essentially the same technique. Traditionally the
process was called screen printing or silkscreen printing because silk was used in the
process. It is also known as serigraphy, and serigraph printing.
Fig : Modern Screen Printing
REFERANCE

1. https://www.slideshare.net/alihossain88/modern-printing-technologies
2. https://canadaprintservices.com/the-5-major-types-of-printing-services/amp/
3. https://www.google.com/search?q=%E2%80%A2%09Screen+printing+process&rlz=1C1GIGM_e
nBD815BD815&source=lnms&tbm=isch&sa=X&ved=0ahUKEwiYoNqyuYrkAhWKso8KHT6tBdQQ_
AUIEigC&biw=916&bih=582&dpr=1.1#imgrc=rp3-jr41KlXFcM:
4. https://en.wikipedia.org/wiki/Inkjet_printing
5. https://www.google.com/search?rlz=1C1GIGM_enBD815BD815&biw=1745&bih=881&tbm=isch
&sa=1&ei=yClZXY-
hBJDYz7sPpvOpqAQ&q=1.%09Continuous+inkjet+printing&oq=1.%09Continuous+inkjet+printin
g&gs_l=img.3...9834.13098..13967...0.0..0.125.1005.0j9......0....1..gws-wiz-
img.WULJyL88vUs&ved=0ahUKEwiPpaSunIzkAhUQ7HMBHaZ5CkUQ4dUDCAY&uact=5#imgrc=c8
Q1mFLIZHVx4M:
6. https://www.google.com/search?q=modern+screen+printing&rlz=1C1GIGM_enBD815BD815&s
ource=lnms&tbm=isch&sa=X&ved=0ahUKEwjIsdTcoozkAhXFQo8KHZL9CMEQ_AUIESgB&biw=17
45&bih=881#imgrc=h_pCrt9zMgMpJM: