Académique Documents
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THEORY
"It is the process by which localized dyeing are produced." It can also be defined as:
PRINTING SCENARIO:
These are the three major criteria's that must be considered for the efficient
production in printing process.
Printing Techniques.
Substrate (Fiber) Type.
Dye Stuff Classes (Colorants)
1. PRINTING TECHNIQUES:
There are five types of printing techniques that are used in the modern textile industry.
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2. FIBER TYPES:
i. Cotton 48
iii. Viscose 15
iv. Polyester 13
v. Others(acrylics,wool,silk,nylon,e 5
tc)
i. Pigments 46
ii. Reactive 27
iii. Disperse 15
iv. Vat 7
v. Others 5
Test Results:
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LAB EXPERIMENT 02
Name: _____________________________________________ ID No.
_______________________
Remarks:________________ Signature of the lab tutor_______________
Date:_________________
Preparation of fabric & paste for printing
PERFORMANCE/OBJECTIVES
THEORY
Textile printing is used to signify the production, by various means of colored patterns on designs
upon all sorts of textile fiber.
Textile printing is the most important and versatile of the techniques used to add design, color, and
specialty to textile fabrics.
Steps of Printing
The basic steps in the printing process are as follows:
6. Afterwashing.
There are many factors encountered for fabric preparation prior to printing, mainly depents on
two factors:
Preparation of cloths:
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Following process are carried out on fabric for printing:
1. Singeing
2. Desizing
3. Scouring
4. Bleaching
5. Mercerization
6. Heat setting
Color preparation:
Print paste is a viscous solution of printing ingredients referred below that is used for textile printing.
The main three printing ingredients are:
1. Dyestuff or pigments
2. Thickeners:
3. Chemicals and waters:
Dyestuff or pigments
For printing color is prepared in paste form. There are two types of paste used:
Pigment paste
Reactive paste
PIGMENTS DYES
Good light stability Relatively low light stability
Recipe:
1000 kg of pigment paste:
Urea 4%
Liquor ammonia 1.4 %
Thickener 4 % (further depends on design and screen)
Binder 3%
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1000 kg of reactive paste:
Urea 15 %
Soda bicarbonate 4%
Resist salt / RG 1.5 %
Thickener 4 % (further depends on design and screen)
Note: IPS machine is used for color paste preparation. In Popular Fabric Mills,
this machine is out of order now days.
Thickeners:
Thickener can be defined as a substance used to increase the viscosity of a print paste or other fluid, in
order to control its flow properties.
Test Results:
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Review Question:
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LAB EXPERIMENT 03
Name: _____________________________________________ ID No.
_______________________
Remarks:________________ Signature of the lab tutor_______________
Date:_________________
THEORY
UREA:
SELECTION OF THICKENERS:
Economical
Compatible with the recommended pH for a particular process.
Non-reactive
Easy removal
BINDERS:
Binders plays key role in pigment printing. Binder is monomers which on heating get converted
into polymers.
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Binder actually hold the pigment color and sandwich it between fabric surface and plastic
coating and this coating help color to stick there and stand with high and severe conditions.
WETTING AGENTS:
A chemical that can be added to a liquid to reduce its surface tension and make it
more effective in spreading over and penetrating surfaces
SOLVENTS:
Solvents are liquids or gases that can dissolve or extract other substances.
DISPERSING AGENTS:
DEFOAMERS:
LIQUOR AMMONIA:
It is used:
To maintain pH towards the alkaline medium, generally up to 10
FIXATION:
BLANK PASTE:
The paste containing all the solutes in water, except colourant (dyestuff) is known as blank
paste.
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LAB EXPERIMENT 04
Printing Styles
OBJECTIVES
THEORY
There are three printing styles that are mostly used in the textile industry.
DIRECT STYLE:
Dye in a thickened formulation is applied to selected areas of the fabric producing a coloured
pattern. Fabric must be pretreated (bleached) and dyed.
Background colour is decolourized due to the discharging chemical from the localized area.
Reactives and pigments are used for this purpose. Fabric is first dyed and printed so that the dye
present in the printed areas is destroyed.
1. If the original white of the fabric reappears, the process is called as a white discharge.
*Sodium Sulfite is the main product for discharge and resist styles.
SEQUENCE OF OPERATIONS:
Dyeing: Conducted by continuous method (pad and dry), but the dye is not
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fixed.
Ground dyeing is always carried out by reactive dyes. Pick up must be 70%
and
controlled drying is carried out at maximum 80C.
Printing: By using direct style and then dyes are fixed.
Soaping: In continuous form.
Special dyes are selected for ground dyeing, which are not compatible with discharging
chemical (sodium sulfite) used in the print paste for discharging. When this paste is applied on
the pre-dyed fabric, it becomes decolourized. For coloured discharging, dyes must be selected
which have compatibility with discharging chemical.
RESIST STYLE:
Dye is applied to a fabric but not fixed. A resist formulation is printed on selected areas of
the fabric. The resist agent prevents the fixation of the dye in subsequent processing. The
unfixed dye is washed away leaving a white pattern. If the resist agent is applied before the
dye, the method is called a "preprint process." If the dye is applied first followed by the resist
formulation, the method is called an "overprint process."
Test Results:
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LAB EXPERIMENT 05
MACHINES
Screen
Sampling machine
THEORY
It is the technique in which screens are used along with the print paste to print the design
onto the fabric.
SCREEN:
It is a perforated sheet having some holes partly opened and some holes partly closed. Screens
possess a particular mesh number:
Mesh number = Number of holes/sq. inch
This number varies depending upon the types of dye and substrate.
Pigment Printing = 4060 mesh no. Reactive Printing = 80120 mesh no. Disperse
(Polyester) Printing = 120150 mesh no.
On the basis of screen shapes, screen-printing is divided into two main types:
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Having horizontal angle of 180 and made up of Nylon.
Vinyl Sulfone type reactive dyes (Low Reactivity) are used for printing purpose.
Drimarene-P (reactive) dyes are produced by CLARIANT for printing.
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Test Results:
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LAB EXPERIMENT 06
Name: _____________________________________________ ID No.
_______________________
Remarks:________________ Signature of the lab tutor_______________
Date:_________________
Block printing of cotton fabric
OBJECTIVES
MACHINES
Wooden blocks
THEORY
Woodblock printing is a technique for printing text, images or patterns used widely
throughout East Asia and probably originating in China in antiquity as a method of
printing on textiles and later paper.
It is the oldest and simplest way of printing. In this method a wooden block with a
raised pattern on the surface was dipped into the printing colorant and then pressed
face down on to fabric. The desired pattern was obtained by repeating the process
using different colors. Generally the wooden block is carved out of hand. Printing is
done manually in this method.
PROCESS
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1. The first step is to sketch the design. It is important to reverse the image if you are using text,
as the printed image will be the reverse of what is on the block. Once you have the image
ready, and then transfer the design on to the linoleum to give an outline of where to carve.
2. The next step is to carve the design. Carve away the parts that you dont want to print, as the
ink will be applied to the raised surfaces to print the design. Whatever surface is untouched
will be what prints onto the paper. Carving a block can take anywhere from an hour for a
small piece, to several weeks or even months depending on the size and detail of the image.
3. Use a range of knives, with very small-tipped knives for carving outlines and details, and
much larger ones for cutting away the background. Carving the blocks takes a lot of patience,
because if your hand slips it can damage the whole piece. With practice, you can learn the
amount of pressure it takes to carve the material.
4. Once the block is carved, trim the excess off with scissors to give it a straight edge, and then
it is ready for printing. There are many different types of ink on the market, and its
important to test them out to find the best one. Use oil-based inks because they give the best
even coverage and print well on both fabric and paper, but there are lots of options out there.
5. The most important part is applying the pressure evenly, since the color will be stronger in
some areas of the print than others if uneven pressure is applied. This is also a step that takes
some practice and perfecting.
6. The ink then takes several days to dry, so unlike other printing processes, there is a long wait
time before the prints are ready to use. The oil based inks can take from two days to a week
to fully dry, whereas water-based inks will dry slightly faster.
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Test
Results:
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LAB EXPERIMENT 07
Name: _____________________________________________ ID No.
_______________________
Remarks:________________ Signature of the lab tutor_______________
Date:_________________
Screen Preparation
OBJECTIVES
MACHINES
Engrave department
THEORY
Screen-printing is the most flexible printing process. It can be used to print on a wide
variety of substrates, including paper, paperboard, plastics, glass, metals, fabrics, and
many other materials including paper, plastics, glass, metals, nylon and cotton. Some
common products from the screen-printing industry include posters, labels, decals,
signage, and all types of textiles and electronic circuit boards. The advantage of
screen-printing over other print processes is that the press can print on substrates of
any shape, thickness and size.
PROCESS
Separating department separates the colors which are made on the sample of papers, piece of
fabric, in CD drive. There are following tasks of this department:
Set the repeat design
Open the congested design
Make pixels on design
Dots in the design of screen
Supplier or costumer gives only their required design in cd format. In cd they also give a form
in which following things are mention:
Number of ways on same design (deign is same but color change)
Number of screen required
Repeat size
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Screen width
Print direction
ENGRAVING DEPARTMENT
1. Rotary engraving
2. Flat engraving
ROTARY ENGRAVING:
Engraving means exposing of design on the screen. These screens are made of nickel.
Following are parameters concern with screen:
Chemical coating:
G.B.M used for chemical coating the screen.
This task is done on coating machine.
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The screen fixed in vertical form.
The chemical put on squeegee.
The squeegee diameter depends on screen diameter.
Time depends on screen length.
Speed of machine is 15-16 m/min for hard coating and 6-7 for light coating.
Climatizer Machine ( Dryer):
This machine is used for drying the chemical coating on screen.
Temperature is set 47-48 oC
Time= 10mins
Exposing machine:
I. Manual machine
II. Ink-jet machine
Manual machine now a days, not used.
Inkjet machine:
CST Ink-jet machine 2011 model
Time for exposing design on screen depends on design & length of
screen.
After completing task, screen is brought into lighting machine in which
light is given to screen. The design area becomes soft and remaining is
hard.
8 round of lighting carriage are given to screen length & about 10-12
min time taken for this task.
Exposing & developing:
Screen is dip on bath containing water for 5-10 min.
After this screen is fixed on rod and pressurized water is giving and soft brush
is rub on screen through that soft area or chemical is taken off from exposed
area.
Ring machine:
Solid ring is fixed at both ends of screen which is fit on print machine.
Adhesive is applied for joining the rings with screen.
Polymer chamber:
This machine is used for drying the adhesive on screen.
Temperature= 220 oC
Time = 10 min
Test Results:
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LAB EXPERIMENT 08
Name: _____________________________________________ ID No.
_______________________
Remarks:________________ Signature of the lab tutor_______________
Date:_________________
Hand screen printing of cotton fabric with pigments
PERFORMANCE/OBJECTIVES
APPARATUS
Beaker
Stirrer
Electric Balance
MACHINES USED
DISCUSION
In pigment printing, insoluble pigments, which have no affinity for the fiber, are fixed on to the textile
with binding agents in the pattern required.
Pigments, of course, are used for the production of plain-colored fabrics, but are of much greater
importance in printing.
1. The pigment can be applied to all fibers potentially and it is the only coloration to glass fiber, fabric
and polyester
4. Possible to produce good combination shades on blended fiber in one padding operation
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5. Application procedure is simple
6. Less expensive
PROCEDURE
First of all, about 1liter of water was taken in a beaker followed by the addition of sodium
alginate 3% and a small amount of ammonia liquor. This mixture was then stirred vigorously
using a high speed stirrer. The viscosity of paste was then measured with the help of
viscometer. The amount of PVA was optimized to obtain a viscosity level of 7000 centipoises
using spindle no. 6 of the viscometer. In the next step, binder was added and again the
viscosity was measured. The increase or decrease in viscosity was noted. A small amount of
PVA was again added to get the required viscosity.
PROCEDURE
Pigment was added in the prepared stock paste and the paste was stirred for some time to
make the pigment paste.
PROCEDURE:
The fabric sample was put on flat bed machine with the screen on the fabric. Print paste was
put on one side of screen and applied with the help of steel rod. Steel rod moved with the help
of electromagnetic assembly and applied the paste on the fabric. The fabric was then dried at
110oC for 1 min through stenter. It was then cured at 170 oC for 2 min. Testing was carried out
on the fabric.
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Test Results:
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LAB EXPERIMENT 09
Name: _____________________________________________ ID No.
_______________________
Remarks:________________ Signature of the lab tutor_______________
Date:_________________
Lab-scale automatic flat screen printing of cotton fabric with
reactive dyes
PERFORMANCE/OBJECTIVES
APPARATUS
Beaker
Stirrer
Electric Balance
MACHINES USED
Dyes = 4gm
Urea = 10gm
Thickener = 50gm
Resist salt = 1gm
Soda ash = 6gm
Additional water = as required.
DICUSION
By the term textile printing we mean the localized application of dyes or pigment and
chemical by any method, which can produce particular effect of color on the fabric according
to the design. In this practical we print cotton fabric with cold brand reactive dyes in block
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and screen-printing methods in combination method. Block printing method is the oldest
printing method. It is used mostly in sarees, handkerchiefs etc. in this printing method we use
blocks of different designs. In screen printing a very little screen made by glass fibre is used.
There are types of screen-printing, but we have done in our experiment was hand screen-
printing. Handscreen-printing is mostly used for sarees to 14-16 colors in on pattern can be
produced at a time.
Preparation of thickener:
PRINTING PROCESS:
Block printing method:
Screen-printing method:
1) The fabric is placed on the printing table of flat screen-printing machine. The table is made
of soft by laying on it.
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2) Then the screen is placed on the sample fabric.
3) The printing paste is taken on the screen perforation.
4) Thus we can find the printed fabric with a smooth wooden strike the paste is spread over
the screen with slight pressure.
5) So that the dye particles can penetrate through the screen perforation.
6) Thus we get printed fabric.
After treatment:
The printed fabric is steamed for 5-10 minutes in a cottages steamer and washed with cold
water for removing unfixed dye and exhausted thickener and then dried.
Conclusion:
Printing of cotton fabric with reactive dyes has excellent build up property and maximum
fixation. Shade is also bright. By this experiment we have acquire knowledge about process
of printing cotton fibres with cold brand reactive dyes in combination shade. The shade of
printed fabric is moderately good, as we required. Special thanks to our teacher and his
assistants for grate cooperation.
Test Results:
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Review Question:
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LAB EXPERIMENT 10
Name: _____________________________________________ ID No.
_______________________
Remarks:________________ Signature of the lab tutor_______________
Date:_________________
Lab-scale automatic flat screen printing of polyester-cotton
blended fabric with Pigment printing
PERFORMANCE/OBJECTIVES
APPARATUS
Beaker
Stirrer
Electric Balance
MACHINES USED
PROCEDURE
First of all, about 1liter of water was taken in a beaker followed by the addition of sodium
alginate 3% and a small amount of ammonia liquor. This mixture was then stirred vigorously
using a high speed stirrer. The viscosity of paste was then measured with the help of
viscometer. The amount of PVA was optimized to obtain a viscosity level of 7000 centipoises
using spindle no. 6 of the viscometer. In the next step, binder was added and again the
viscosity was measured. The increase or decrease in viscosity was noted. A small amount of
PVA was again added to get the required viscosity.
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CHEMICAL REQUIRED (for print paste)
PROCEDURE
Pigment was added in the prepared stock paste and the paste was stirred for some time to
make the pigment paste.
PROCEDURE:
The fabric sample was put on flat bed machine with the screen on the fabric. Print paste was
put on one side of screen and applied with the help of steel rod. Steel rod moved with the help
of electromagnetic assembly and applied the paste on the fabric. The fabric was then dried at
110oC for 1 min through stenter. It was then cured at 170 oC for 2 min. Testing was carried out
on the fabric.
Test Results:
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Review Question:
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LAB EXPERIMENT 11
Name: _____________________________________________ ID No.
_______________________
Remarks:________________ Signature of the lab tutor_______________
Date:_________________
To determine viscosity of printing paste
PERFORMANCE/OBJECTIVES
Upon the successful completion of this experiment, the students will be able to understand:
APPARATUS
Digital Viscometer
Printing Paste
DISCUSSION
Viscosity of printing paste is very important because it influences the clarity and appearance
of printed pattern. It maintains sufficient elasticity and plasticity of film coating on the fabric
after printing and not to flake or crack when dry.The capillary actions caused by the dye to
run can also be prevented by maintaining viscosity. It also provides easy flow in the screen
while printing operation is continued.
Mostly the viscosity is maintained by using thickener and liquor ammonia or other alkalis.
Thickeners are added to the printing past to produce viscosity which is necessary to ensure
sharp definitions. If the viscosity of printing paste is high then Haloing effect fault is
produced and if the viscosity of printing paste is high then Flushing effect fault is
produced.
According to the standard conditions for printing, the paste viscosity should be between
7000- 8500 mPa.
PROCEDURE:
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Test Results:
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LAB EXPERIMENT 12
Name: _____________________________________________ ID No.
_______________________
Remarks:________________ Signature of the lab tutor_______________
Date:_________________
To determine rubbing fastness of pigment printed fabric
by ISO 105 x 12 method
PERFORMANCE/OBJECTIVES
Upon the successful completion of this experiment, the students will be able to understand:
APPARATUS
Crock meter
Rubbing Cloth
Grey scale
DISCUSSION
Loss of color when textile material is rubbed against various surfaces is known as lack of
color fastness to rubbing. Reason for poor rubbing fastness is loosely held dye molecules on
the surface of the fabric.
Crock meter is the apparatus used to determine rubbing fastness of dyed or printed textile
materials. Fabric are tested for checking their rubbing fastness using wet and dry rubbing
cloth, called wet rubbing and dry rubbing respectively. Rubbing cloth used for this purpose is
5 x 5 cm desized and bleached cloth on which few drops of water are pored in case of wet
rubbing, otherwise dry cloth is used.
PROCEDURE:
1. Cut two pieces of fabric to be tested having their dimensions not less than 14 x 5 cm.
2. Fasten the samples on the baseboard of crock meter with the help of clamps.
3. To determine rubbing of multi-colored fabric fix and check rubbing of each color
separately.
4. With the dry rubbing cloth flat in place over the end of finger of testing device, rub to
and fro in a straight line along a track 10 cm long on the dry specimen at 10 cycles per
10 second downwards force of 22N or 9N.
5. Repeat the process for wet rubbing with a fresh dry specimen and with a rubbing cloth
that has been wetted with water by placing it on the grating and dropping evenly on it
its own mass of water or use any method to ensure a take-up of about 100%. After
rubbing dry the cloth at room temperature.
6. Asses the staining on the rubbing cloth using grey scale.
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LAB EXPERIMENT 13
Name: _____________________________________________ ID No.
_______________________
Remarks:________________ Signature of the lab tutor_______________
Date:_________________
Digital printing of textiles
PERFORMANCE/OBJECTIVES
DISCUSION
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Features Digital Printing of Textiles
Flexibility
Reduced setup
costs
Small batches
Variable data
Design freedom
Process enhancement
Low waste
Customised products
Design innovation
No stock
Innovation
Novel inks
Product security
Nanotechnology
MACHINES USED
Dream ink jet printer
DuPont 3210
Speed 30 -60sq m / h
Width 3.2 meter
360 dpi (Good quality)
8 color system
DuPont 2020
Speed 30 sq m / Hr.
Width 1.8 M
720 dpi
8 color process
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