PRINTING TECHNIQUES

BURN OUT PRINTING: This is a rare quality print. Burnout print is also very
expensive too. It's a very nice quality print. The printing factory makes this
print with the flat bed printing machine. The printing way of this print is
same as a normal flat bed print, just printers use acid type chemical instead
of color.

We can do this print only some selected fabric. This print is not possible on
100% cotton fabric. The best composition for this burn out print is 60%
polyester and 40% cotton fabric. This print is also possible on 60% cotton
and 40% polyester.

The main technique of burnout print is destroys the cotton portion of the
fabric with Acid / Chemical. When the chemical flow over the fabric and
contact with cotton portion, then it burn out the cotton by chemical
reaction. An acid paste is printed on a poly cotton blend. As it is heated in
the dryer it eats away the cotton, leaving just polyester weave behind. It
has to be washed and treated with soda ash to neutralize the strong acid.
Actually cotton is the victim here.
Chemicals of Burn Out Printing:
1. PC or CVC fabric.
2. Paste + Any acid liverating salt (like Nacl, Na2 so4)
3. Steaming
4. Washing (Roubasting wash)
5. Burnout print complete
Step by Step Printing Process of Burn out Print:

1st Step: Develop the print design and screen with the buyer provided
artwork.

2nd Step: Knit the fabric with the yarn of following composition

a) 60% polyester 40% cotton OR
b) 40% polyester 60% cotton Or similar like that.

3rd Step: After complete the kitting of fabric send the gray
or scouring fabric to printing factory.

4th Step: Perform the print on this fabric. Here, the cotton part will be
destroyed by the acid but polyester portion will be remain same.

5th Step: Then we will dye and finished the fabric as per our require color
Important points regarding the Burnout print:

1. Burnout print is not possible on 100% cotton fabric. Clothes should be PC
or CVC
2. 60% polyester 40% cotton is the best composition for Burnout print.
3. Process loss is very high. More than 35%
4. Single jersey construction is the best construction for Burnout print.
5. If you need the finished fabric with 120 to 130 GSM then you should knit
the fabric with 160 to 170 GSM.
6. Burnout print is not only expensive but also lucrative with nice feelings.
BLOTCH PRINTING: In it the background as well as design motif has been
printed on (not dyed). Unless the fabric is very light weight , the printed
color will not penetrate well enough to show as strongly on the back as the
face, this naturally gives less solid looking ground.
DUPLEX PRINTING: It is achieved by printing both sides of fabric either in
the same pattern or with different designs on each side. Duplex Printing
Printing is done on both sides of the fabric either through roller printing
machine in two operations or a duplex printing machine in a single
operation.
STENCIL PRINTING: Stencil Printing The design is first cut in cardboard,
wood or metal. The stencils may have fine delicate designs or large spaces
through which color is applied on the fabric. This method is very expensive
and thus its use is limited.
SPRAY PRINTING: Jet Spray Printing Designs are imparted to fabrics by
spraying colors in a controlled manner through nozzles.
PHOTO PRINTING: Photo Printing The fabric is coated with a chemical that
is sensitive to light and then any photograph may be printed on it.
DIGITAL PRINTING: Digital printing In this form of printing micro-sized
droplets of dye are placed onto the fabric through an inkjet printhead. The
print system software interprets the data supplied by academic_Textile
digital image file. The digital image file has the data to control the droplet
output so that the image quality and color control may be achieved. This is
the latest development in textile printing and is expanding very fast.
INKJET PRINTING: Inkjet printing is a type of computer printing that
creates a digital image by propelling droplets of ink onto paper, plastic, or
other substrates. Inkjet printers are the most commonly used type of
printer,
[1]
and range from small inexpensive consumer models to very large
professional machines that can cost tens of thousands of dollars, or more.
There are two main technologies in use in contemporary inkjet printers:
continuous (CIJ) and Drop-on-demand (DOD). 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 gunbody and a microscopic nozzle, creating a
continuous stream of ink droplets. A piezoelectric crystal creates an
acoustic wave as it vibrates within the gunbody 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 neighbouring droplets. The charged
droplets pass through an electrostatic field and are directed (deflected) by
electrostatic deflection plates to print on the receptor material (substrate),
or allowed to continue on undeflected to a collection gutter for re-use. The
more highly charged droplets are deflected to a greater degree. Only a
small fraction of the droplets is used to print, the majority being recycled.
The major advantages are the very high velocity (~50 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), and from the venting process
whereby air that is drawn into the gutter along with the unused drops is
vented from the reservoir. Viscosity is monitored and a solvent (or solvent
blend) is added to counteract solvent loss.
Drop-on-demand (DOD) is divided into thermal DOD and piezoelectric DOD.
In the thermal inkjet process, the print cartridges contain a series of tiny
chambers, each containing a heater. 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 to form a bubble, which causes a
large pressure increase, propelling a droplet of ink onto the paper. The inks
used are usually water-based and use either pigments or dyesas the
colorant. The inks used 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.
Most commercial and industrial inkjet printers and some consumer printers
use apiezoelectric material in an ink-filled chamber behind each nozzle
instead of a heating element. When a voltage is applied, the piezoelectric
material changes shape, which generates a pressure pulse in the fluid
forcing a droplet of ink from the nozzle. Piezoelectric (also called Piezo)
inkjet allows a wider variety of inks than thermal inkjet as there is no
requirement for a volatile component, and no issue with kogation (buildup
of ink residue), but the print heads are more expensive to manufacture due
to the use of piezoelectric material (usually PZT, lead zirconium titanate). A
DOD process uses software that directs the heads to apply between zero to
eight droplets of ink per dot, only where needed. Piezo inkjet technology is
often used on production lines to mark products. For instance, the "use-
before" date is often applied to products with this technique; in this
application the head is stationary and the product moves past.
Requirements of this application are high speed, a long service life, a
relatively large gap between the print head and the substrate, and low
operating cost.
TRANSFER PRINTING: Transfer Printing In this method, The design on a
paper is transferred to a fabric by vaporization. There are two main
processes for this- Dry Heat Transfer Printing and Wet Heat Transfer
Printing. Various types of cylinders such as electrically heated cylinder,
perforated cylinder etc. are used for pressing a fabric against a printed
paper which transfers the pattern to the fabric.
ELECTROSTATIC PRINTING: Electrostatic Printing A dye- resin mixture is
spread on a screen bearing the design and the fabric is passed into an
electrostatic field under the screen. The dye- resin mixture is pulled by the
electrostatic field through the pattern area onto the fabric.
Tie Dyeing
Tie Dyeing Firm knots are tied in the cloth before it is immersed in a dye.
The outside portion of the immersed fabric is dyed but the color does not
penetrates the inside portions of the tied knots. There are various forms of
Tie dyeing like Ikat Dyeing where bundles of warp and/ or weft yarns are tie
dyed prior to their weaving. In Plangi Dyeing the gathered, folded or rolled
fabric is usually held with stitching to form specific patterns.
Batik Dyeing
Batik Dyeing It is a resist dyeing process. Designs are made with wax on a
fabric which is then immersed in a dye. The portion not having wax absorbs
the color.
Roller Printing
Roller Printing In this method which can be called a machine counterpart of
block printing, engraved copper cylinders or rollers are used in place of
hand carved blocks. When the rollers move, a repeat of the design is
printed on the fabric. The printed cloth is passed into a drying chamber and
then in a steam chamber where the moisture and heat sets the dye.