Applications and Solutions of Digital Printing Textiles

1
Applications and Solutions of Digital Printing
Textiles
Instance

• FAQ and solutions for ink which used for textile

2
Part 1. History and Prospects for
Digital Printing

• Digital ink-jet printing is one of the promising
  of multitude ink-jet printing technology

3
Part 1. History and Prospect for Digital
Printing

• Whats digital ink-jet printing

Digital ink-jet printing is one of the promising
of multitude ink-jet printing technology
4

• Concept Digital ink-jet printing

• In brief, digital ink-jet printing is make the
  pattern to digital form and put on the computer,
  thorough editorial processing by the
  pattern-designing system for fabric printing,
  then printing on textile or on the certain media
  then transfer to textile which controled by the
  company..

5

• Concept Digital ink-jet printing

• Digital ink-jet printing is a system engineering
  which comes down to CAD technique, network
  communication, precision machining technique and
  fine-chemistry technology. It is a product melted
  by information technology, textile and Chemicals
  etc.

6

• Concept Digital ink-jet printing

• With the gradual development of computer
  technology, Digital ink-jet printing is a hi-tech
  product which combines machine, electronic
  information technology. It dates back to ninties
  of 20th century. The birth and development of
  digital ink-jet printing bring a new concept for
  textile and dyeing industry. The advanced
  manufacturing principles and method in digital
  ink-jet printing technology brought unprecedented
  opportunities of development in textile and
  dyeing industry.

7
Development for digital ink-jet printing

• Summary on the development of digital ink-jet
  printing

8
Summary on the development of digital ink-jet
printing

• Digital ink-jet printing has the same principle
  with inkjet printer. But the inkjet printing
  which dated back to 1884 and entered the
  practical stage in 1960. 90 of the last century,
  computers started to become more available to the
  public, dropondemand inkjet printer appeared in
  1995. From 1999 to 2000, the printer adopted
  piezo print heads showed at many countries. Now
  the development of the digital printing
  technology presented competitive market.

9
Summary on the development of digital ink-jet
printing

• in recent year, with the rapid development of the
  textile printing, the printing volume
  synchronization grows. At the same time, the
  fashiona cycle is shorter and shorter, the
  pattern become more and more, the production
  requirement become higher and higher, the order
  become smaller and smaller. Base on the
  traditional prting, although the printing company
  absorbs CAD printing system, laser imager, flat
  screen printing, rotary screen printing, Wax
  spraying printer etc. the dye factory is a
  pollution plant has deep influence to people. At
  the same time, on international basis, the
  printing products of our country was hindered by
  the non-trade barrier more and more serious. On
  the current technology, digital printing is the
  best method to slove the most problems in
  printing area.

10
Summary on the development of digital ink-jet
printing

• No matter the flat screen or rotary
  screen printing, both of which can not without
  screen, the cost and the time spend on making the
  screen can not satisfied the modern printing
  which in diverse, small-batched production.
  Therefor the digital printing which without
  screen and press was developed. The basic
  principle of digital printing is same as inkjet
  printing.
• The inkjet printing technology can dated back to
  1884. C.H. Richard puted some water in injector,
  given pressure to the water, from pinhead would
  dash off dropping. If can control the directions
  of the dropping, the pictures will be made one
  the paper, this called inkmist printing. Because
  of the pinhead and the ink, the printing result
  was very bad at that time. The inkmist printing
  came into practise untill 1960. During last 10
  years, the printing techonology used in making
  bar-coding and sequence number, which named Fog
  ink printing. Because of the neddle and the ink
  at that time, it had a Poor result. Until 1960 it
  was formally enter the practical stage. a decade
  ago, the ink-jet technology for processing or
  product serial number bar code printing, said
  inkjet printer.

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Summary on the development of digital ink-jet
printing

• As the digital inkjet printing technology
  involves a large calculation and control, it can
  be said without high-speed computers on today,
  there can be inkjet printing technology. For now,
  the development of digital inkjet printing
  technology and the skills in computers are
  synchronous. Till now, the development of
  computer technology shows no sign of subsiding.
  With the development of computer technology, it
  is foreseen that the digital inkjet printing can
  also develop with high speed in the future. At
  the same time, manufacturing of printhead also
  has benefit from the development of integrated
  circuits, such as etching, precision assembly
  etc. Now the high-frequency, multi-nozzle of
  printheads appeared out frequently to prove it.

12
Summary on the development of digital ink-jet
printing

• In 90s, computer ttechnology gradually universal,
  contiuous digital jet printers appeared, the
  usage in ragged textiles such as carpets, wall
  hangings etc became mature. Zimmer in Austria
  first exhibited the digital jet printers which
  printed on carpets the resolution is 9-18. Using
  spray valve technology but not the printheads,
  the speed can be 16/min. But because with the big
  dots, the resolution is very low, so this
  technology can not print on garments.

13
Summary on the development of digital ink-jet
printing

• In 1995, drop-on-demand inkjet printers appeared.
  It adopted thermal foam printhead, with 300 dpi,
  gradually developed to 600dpi, 4 colors and can
  printing on garments.
• 1999-2000, adopting piezoelectric printhead
  printers were exhibited in many countries,
  including Netherlands, Japan, Switzerland, the
  United States, Italy, China (Atexco). The
  printers resolutions can reach to 360-720dpi,
  6/h. Because of little min ink amount, meticulous
  printing image, natural colors, piezoelectric
  printheads became popular and the applications
  was extended.

14
Summary on the development of digital ink-jet
printing

• At present, a variety of new digital printer have
  been appearing, mainly use piezoelectric
  printhead. The highest speed from 1/h in 90s, 6/h
  in 2000 developed to 080-150/h, the dye ink from
  4 colors developed to 6-8 colors and 2X6-8
  colors. The application technols have basically
  formed. The fuctions of control software has been
  tended toward perfection. Thus,digital inkjet
  printing technology developed from continuous
  shooting to on-demand jet, from thermal foam
  printhead to piezoelectic printhead, from 4
  colors to 6-8 colors.

15
Summary on the development of digital ink-jet
printing

• There is no doubt that the appearance and the
  application of digital jet printing technology is
  a great technological revolution in textile
  industry. It is a milestone of great
  significance. Digital printing brings huge
  economic and social benefits to the world
  especially to China which has strong prow in
  textile printing and dyeing.
• The same as other industrial upgrading and
  change, the appearance of digital jet printing
  technology is is an opportunity as well as a
  challenge, chinese textile industry must seize
  the initiative in the coming changes.

16
Current situation of ditial printing technology
Now around the world, digital inkjet printing
technology are contending for hegemony. Stork in
Holland, artistr2020 in Japan, NASSENGER of
KONTCA NIMOLTA, Reggiani in Italy, DGI in Korea,
Atexco in China etc. are in the fierce rivalry
for this new and huge market.
17
Current situation of ditial printing technology

• innovation and independent printhead technology

18
Innovation and independent printhead technology

• After inkjet printers installing with
  piezoelectic DOD printhead of EPSON, Which
  improved by the engineers who specialized in
  printing area, the digital printing technology to
  be universal. Many manufacturers of printhead did
  not pay attention to the applications in this
  area, after seeing this huge potential market for
  textiles, they are actively developing
  water-based heads which use in the digital
  printing industry. Seiko, Konica, Ricoh in Japan,
  NOVA-AAA of SPECTRA IN America, mnidot760 of XAAR
  in England, Aprion in Israe are developed
  corresponding printheads. Now some of them are
  successfully used in textiles printing area.

19
Innovation and independent printhead technology

• In recent years manufacturers of printheads and
  printing machines are participating in this
  industry to imporve the technolgy, and now some
  machines can simultaneously use a variety of
  different types of ink(such as active, acid,
  dispersion, paint etc.). the frequency of
  printing is also promote(15-25khz). The nozzles
  of one printhead are increase. All of this are
  provide a good platform for increasing the
  production of printing. Life-time dilation(the
  printhead of Aprion Israe can be use more than 2
  years without problem.), the cost for making each
  nozzle llessens at least 30, thus the cost
  during production of digital printing, the cost
  for the printhead became low. Therefore the
  advance of printhead technology bring a new and
  prosperous scene.

20
Innovation and independent printhead technology

• At present, there are three types of printers,
  they are low speed, middle speed, high speed.
  After years of effort, many companies skilled
  transform the water-based printer to the printer
  which can suitable for printing on textile. Now
  the functions of this kind of printer are
  relatively perfectly, each water-based printer
  has all the functions of the traditional printer
  which can be see this kind of printer. The
  practical production is 12M2/H for this printer
  which only can use for printing samples.
  Therefore many people consider when the speed of
  digital printing reaches to 25M2/H can satisfy
  the require of production. It is our view that
  the middle speed printer.

21
Innovation and independent printhead technology

• At present there are a few companies in the world
  production of this printer, such as early
  Robstrlli which produced Monna Lisa, Artistri
  2020 which produced by Dupont (OEM by Dongshen
  Japan). The Nassenger V printer produced by
  KONICA MINOLTA last year, the VEGA printer
  produced by Hongkong China had been shown on the
  second session of the Asia ITAM 2005 Expo caused
  a lot of interest in visitors. They adopts 32
  printheads, now the normal printing output is
  23M2/H, Through technology upgrading the output
  can reach to 28M2/H, If adopting the dual-beam
  structure, the production can be doubled. Since
  this printer is not a simple transformation of
  low-speed printer, It uses stainless steel
  water-based piezo DOD printheads, and is
  different from the one used in the printer which
  produced by other companies. And this printer has
  self-respect and core technology, which proved
  that China's production technology of digital
  printers have been with international standards.

22
Innovation and independent printhead technology

• Reggiani introduced 1.6M DreAM high-speed printer
  in the second year, since now there are 20 units
  around the world, this year, it launched 2.2M
  printer which had improved. A lot of features and
  performancem had a new improved. Its speed has
  been increased from 150 M2/H in the past to the
  present 190 M2/H. Soon they will also introduce
  3.2M printers. We should particularly concerned
  OSIRIS DIGITAL PRINTS Dutch which produce a
  continuous print mode of the digital printer.
  Their newly developed printer with the belt speed
  of 18 m / min (Its about ten times of DreAM),
  printing width is 1600mm. So the output of this
  printer can reach to 1700M2/H. The price was set
  at 3 million euros per set. The printer will be
  finished at the end of the year, next year could
  be sold. If this machine can be formally used in
  the production, it will be a big impact to
  traditional machine.

23
Prospect of digital printing technology

• Which is the perfomance for disadvantages and
  advantages of digital print?

24
Advantages of digital inkjet printing

• Comparing the digital print to traditional
  print,the following are some advantages for
  digital print
• 1.No version print   
• The digital print change the process Routing
  of the traditional print,neednt make printing
  version,the color pattern can directly show on
  the textile through the process of the computers
  digital image. It is not only save the workstage
  of screen production, substantially cut down the
  printing time,and the management of screen can
  directly become the computure data, save room.

25
Advantages of digital inkjet printing
2. The printing effect will be more rich,more
fine,more layering. The technology of digital
printing break the printing register and the
length of printing back for traditional printing
restriction,can creat the very perfect smooth
level and vivid photo effect.Now the digital
printing can express the unlimitedness of color
quantity in theory.,expand the designed space of
the textile pattern.
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Advantages of digital inkjet printing

• 3.Small quantities and rapid reaction
• The Production quantity of digital printing
  cant be limited by anything,the process can be
  controlled by computer, it can be traded on day
  or take delivery, have done the quick reaction to
  market,and can satisfy the requirment of customer
  individuation design.
• 4.Labour-Saving
• Comparing to the larg scale equipment of
  traditional printing, digital printer are small
  equipment,one worker can operate many equipments,
  and the trainning of digital printing operators
  are faster than the trainning of traditional
  printings.

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Advantages of digital inkjet printing
5.Come true the clean production The
digital printing jet by computure according to
needing( the deflection droplet during the
constant spary will be automatically collected to
the system),there will no discharge slurry,with
the small noise of JUMP model,little waste
water,less energy consuming,is one cleaner
production process.
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The disadvantages of digital printing

• The disadvantages of digital printing    
• 1.The technical difficult level are rather high
• Digital printing is a comprehensive new industry
  with multidisciplinary and multi-field.
• Due to the subject developing restriction of
  Machine,Electron,Chemicals,Computer,etc, it is
  necessary connecting all of these subjets
  development to make digital printing
  developing.At present, the development of various
  subjects influence the development of digital
  printing,and seriously lack of comprehensive
  talent in digital printing industry.   

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The disadvantages of digital printing
2. The production of digital printing are rather
low ? Because the digital printing be influnced
by the presented development of
Electron,Chemicals Etc which seriously
influence the huge production of digital
printing. Especially the technology of printhead
cant come true the huge scale production ?
There is more limited for digital printing in
Chemicals side,needing the good ink with
fluency,Viscosity,color,precision(the resolution
of ink particles and inkjet point),dry speed
during high speed inkjet ? It is high
requirment for the machines precision during the
high speed inkjet.it is the normal printing when
digital print,it requires to cooperate with the
highest machines hard precision and CNC
precision very well.
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The disadvantages of digital printing

• 3.there are some difference between digital
  printing colour,gaumt and traditional printing
• Due to the restriction of ink hue of digital
  printing,and the restriction of original ink hue,
  digital printing is more narrow comparing the
  traditional printing paste gamut.
• Though digital printing can show the 1670Million
  color which comes from the mixed 4 color,8
  color,12 color,the traditional printing has more
  special color in practiacal production.

31
The developing trend of digital printing
Though there are many technical
disadvantages,there are many advantages which are
much better than traditional printing for digital
printing ,and the disadvantages of digital
printing can be overcame and perfected by the
current high speed technology development.
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The developing trend of digital printing

• (1)Promot the method of production and the
  operating model
• Long term since the restriction of traditional
  process,the enterprise can make profit when the
  printing products reach some scale and quantity.
  With the development of economic,the market
  needing trend more and more diversification,person
  alized.The difficuty questiona around the
  enterprise long term be resolved with the
  occruing of the digital printing. At the past,
  one product be finished needing few days even
  several days from the design to delivery, now the
  customer choose well the pattern and fabric, the
  finished product can get only 2 hours,it can well
  satisfy the personalized needing of customers
  dress or decoration. Someone predict the digital
  technology will connect with net by the high
  speed in 21 century,in order to come true the
  personalized,one to one made-to-measure operating
  model.

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The developing trend of digital printing

• (2)Maximum satisfy the customers personalized
  needing, Improving people's life quality.
• For the textile designer, it is extremely good
  tool to show individual creativity, make them
  fully display creation ability,will change the
  best ideal thing into the reality product.
  Digital printing color is rich,adopting four
  color and special color can print the 1670million
  color.For the customers, can have individual
  design according to personalized favoriate from
  home to tourism products. In this sense,a new
  technology will drive a new market,stimulating
  new consuptiong demand.

34
The developing trend of digital printing

• (3)Digital printing will directly promote the
  development of"green textile" and "green
  manufactur".
• Due to the digital printing directly install
  the dye liquor into the special box according to
  the needing to inkjet the fabric. It is not only
  no waste,but also no waster and sewage
  water,reach the purpose of printing no waster.and
  save the film. Saving Screen mesh, yintong. It
  is not only relife the burden of enterprise,but
  aslo come true the envoriment requirment.

35
The developing trend of digital printing

• The trend of digital printing in our country

36
The developing trend of digital printing
In recent years,chineses textile and
pigment printing develop by faster speed, the
printing production was increased. In 2001, the
printing production reach 178.3 million
meters,among printing fabric 43.67 million
meters, stand the printing production
24.41,increased to 11.82, in 2002 national
printing production 210.87 million meters, 18.34
growth, among the printing fabric has 49.86
meter, increase to 14.18 million meters,
increase the yield of printing and dyeing,
23.57, In December 2003, 1-251.32 million meters
of printing and dyeing production year-on-year,
is 20.43 and printing production have yet to be
announced, if press, 2002 (23) calculated the
proportion of 2003, China printing yield
estimation for 57 million meters.
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The developing trend of digital printing
38
The developing trend of digital printing
Although the digital printing have a small
market share among the whole printing.Due to the
many advantages of digital printing,and State
strongly support and promot the development of
digital printing so that the digital printing
keep the high-speed development.
39
The developing trend of digital printing
Although digital printing will not sure to be
fully replaced traditional printing in futur,
digital printing will occupy large deodorants in
printing industry in the future.
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Part 2, the program of digital printing

• The reactive dye printing

• Disperse dye printing

• Acid dye printing

• Textile coating

• Other type digital printing

41

• Reactive Digital Printing

Reactive dye printing mainly be used the
following fabric printing Cotton,Hemp, Viscose
fiber and silk
42

• Cotton,Hemp, Viscose fiber and silk

Reactive dye printing processes Cotton
silk bleaching---Rolling alkali (2 calcined soda
10urea seaweed glue some salt adequate)
---drying--- reactive dyes inkjet printing and
QiZheng (102? 8 minutes)-- water
washed---soaping--- drying stereotypes.
43
Reactive Digital Printing
The reactive printing fabric is color bright,
better colour fastness, soft feeling, it can wash
not fade, as new. Printed fabrics apply more
extensive group.
44

• Digital printing disperse dyes

Dispersive dye printing fabric printed below
mainly be suitable for Most fiber fabric and
partial modification fabrics
45

• Digital printing disperse dyes

Disperse dyes printing process can be divided
into two kinds paper transfer and
direct-injection Paper Transfer inkjet
printers use thermal transfer printing heat
transfer paper? the use of transfer printing
machine at 180 220? or so to transfer designs
to fabric above (the flowers of the method leads
to a relatively high degree of precision, but the
effect of dual-permeability relatively poor).
46

• Digital printing disperse dyes

Scattered Digital Direct Injection scouring
and bleaching fabric mercerized?fabric
sizing?Digital direct-injection?high-temperature
hair color (the kinds of methods of production
printing fabric flowers than fineness of the
fabric transfer paper,but the better-performing
dual-permeability).
47

• Digital Printing Acid Dyes

Acid dye printing fabric printing mainly
applies to the following Most of the protein
fiber, nylon, acrylic fabrics, etc.
48

• Digital Printing Acid Dyes

Acid Dyes digital printing process as
follows    scouring and bleaching fabric
mercerized ?coloring (pulp powder (guar soybean
meal), ammonium sulfate, urea, glycerol, or
glycerol A and anti-microbial agent and defoamer)
? drying ? acid dye-based ink jet printing ?
steam (102 ?, 20 40 minutes) ? water washing ?
soap ? washing ? drying stereotypes
49

• Digital Printing Acid Dyes

Acid Dyes printing color, handle and fastness
are better. Craft relatively high degree of
difficulty, suitable for printing high-grade
fabrics.
50

• Digital Printing Textile Coating

Textile pigment printing fabric printing
mainly applies to the following Most of the
plant fibers, viscose fibers and blends a variety
of fabric printing.
51

• Digital Printing Textile Coating

Digital Printing Textile Coating Process
Mercerized fabric scouring and bleaching ? Paint
?curing ink jet printing directly fixing (or
Pressing fixing) ?curing agent on the solid
color? curing
52

• Digital Printing Textile Coating

Textile Coating digital printing process is
simple, applicable to a variety of fabric
printing. Its energy consumption is relatively
minimal, and no need water no sewage produced.
Deficiencies is, due to the current adhesive
technology constraints, rubbing fastness is not
high, less bright colors.
53

• Other types of digital printing

As present, the digital printing
technology is in its development stage, the
various companies and organizations are combining
traditional and new technologies available for
development of new printing technology, so that
the types of digital printing technology is
constantly growing. Appeared, laser digital
printing, water transfer, cold transfer, and so a
new printing technology.
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Part 3. Digital printing common problems and
solutions
As digital printing is a new printing
technology, the inevitable emergence of a
relatively large and complex issues. And most
customers are not relevant in the digital
printing field experience and technical
capabilities, which requires us to have more
professional and extensive knowledge of various
disciplines, and have strong analytical problems
and provide solutions to the client capability.
55

• Digital Printing Frequently Problems

• How to find digital printing problems?

56

• Digital Printing Frequently Problems

• If we want to find the problems during the
  digital printing process,we must be very familiar
  with digital printing process every step of the
  whole. Only the steps in each process is very
  in-depth research and overripe in mind, in order
  to succeed in discovering the problem and solve
  the problem.

57

• Digital Printing Frequently Problems

Original cloth processing
Sizing stereotypes
Print on the printer
Paint Miao draft
Separation Calibration
drying finishing
gas evaporation color
soaping washing
58

• Digital Printing Frequently Problems

washing
soaping washing
solid color stereotypes
Storage, Transport
59

• Digital Printing Frequently Problems

• When we are familiar with each step of the
  digital printing,we can judge why the problems
  happened.

When we have not identified the
problem,should be taken to analyze the problems
related to the biggest key factor. To take the
simple to the complex, from big to small, from
direct to indirect, from the key to a secondary,
with the elimination process to identify the
problem When in solving problems, and the
need to comply with the relevant provisions of
the company,to solicit customer feedback, and
there are special circumstances when there is no
100 certainty solution,must seek the views of
the company or direct supervisor.
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• Digital Printing Frequently Problems

For example color printing products appear
chromatic aberration. We must first check
whether it is because the state of the inkjet
printing machine whether has a fault.
Second, check the image color adjustments are
correct. Third, check the steaming machines
and whether the process of steaming has problems.
Fourth, check the sizing is normal.
Fifth, check if the print environment is unusual
and so on..
61

• Digital Printing Frequently Problems

• As another example Domestic roland fj 740 has
  been modified belt-type digital printing machine
• has some of the problems.
• print images in a clear break streak
• Analysis
• 1. Print nozzle test,to see if bad break.
• If the disconnection is due to the nozzle
  that caused Broken Needle. At this point, should
  check whether the ink sac blockage or air pipes
  smooth, spray the surface of dirty, scraping
  tablets and ink stack is a normal working
  environment is normal, whether there are
  impurities in the ink. Forward to solve the
  problem one by one.
• 2.Check the conduction band step are whether
  normal.
• 3.Check the print head whether need for
  calibration.

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• Digital Printing Frequently Problems

• In short, no problems before the need to
  strengthen learning, expand their depth of
  knowledge and expertise. In case of problems, and
  the need to increase patient,careful and
  increases sincerely to analyze the problem to
  solve the problem to consult problem-solving
  approach. Also, solve the same problem this time,
  next time will not be your problem.

63
Thanks