In carpet frame TC cotton are arranged into warp
direction.
Hand knotting actually done in TC yarn by wool
yarn.
Pile height depends on the carpet design and
types.
Knotting depends on the carpet length and
height.
The knotting by the worker hand.
Every warp yarn insert in to heald eye.
There heald shaft used to yarn the held eye.
There two sites of warp yarn used to in warp
direction.
When inside knotting finished then the heald
shaft need to turn up or down.
Then another side knotting has to be done.
In above way knotting and backing of carpet can
be produced.
Shearing and Trimming:
Objective of Shearing and Trimming:
To equal the pile height carpet.
To remove extra knotted pile from carpet.
Procedure:
First have today down the carpet
Then have to cut the extra pile by knife.
Then have to wash the extra pile from the
surface of carpet.
Final Touch and Finishing:
Objective:
To improve the quality of carpet.
To sew the backing of carpet.
To suitable for market.
Procedure:
First we have to cheek the pile height of carpet.
Then we have to equal the pile height by using scissor.
Then final have final inspection the carpet quality of carpet.
Senior Project program send us to the expected destiny of
practical life. The completion of project work at, we have got the impression
that the factories are the Carpet manufacturing
in Bangladesh. Though it was established
from a long time, it has earned very good reputation for its best performance
in Bangladesh Market.
During our senior project program we had tried to our best to done our duty. It is completely a new experience in our life. Although we had some barrier during project, but lastly we recover it and which will be very effective in our service life. During our project period we realized that practical experience is valuable for service life.
First of all the authors express our gratitude to supreme
Allah for blessings, approval, protection, mental power and wisdom in all
aspects of our life. The applauses to Allah to complete this project work. This
work has been carried out at different carpet factory, Department of Textile
Engineering, City University. During the thesis work, many individuals have
unselfishly contributed their time, support to make this project possible. We
would like to extend our sincere gratitude to those who have provided guidance
in every step along the way.
The authors deeply indebted to our honorable supervisor Lecturer,
Department of Textile Engineering, City University. Our honorable supervisor encouragement
helped us in all the time of research for this thesis. Her scientific
curiosity, encouragement and guidance throughout this work have been necessary
for this thesis. She helped us every moment during this Project. Without her
help it was quite impossible to do this project.
Rotary-screen printing machine used for both carpet printing and textile printing but the main difference of the rotary screen printing machine depend on between the carpet and other textile printing according to the type of squeegee used. All carpet squeegees are considerably larger and wider opening end rings are used. The standard print width is usually 4 m, so considerable storages space is needed for many screens and design used by a typical carpet factory. The screens are made by Galvono Nickel of a fairly heavy gauge (0.3-0.5 mm thick) with a much coarser mesh(20-30).Lacquer screens are not used for carpet printing. Standerd rotary screens give a repeat pattern of 1 m but a larger screen can give repeat sizes up to 3 m printing of oriental carpet designs. Read about Offset Printing Machine
Advantage of the Rotary- Screen Printing Machine:
More productive than older flat screen machine.
Print speed is 15-20 m/min.
The machine occupies much less space.
Labor costs are lower.
With actuating mechanism it is possible to print
repeat pattern 2-3 m for bordered oriental square designs.
Disadvantages of the Rotary- Screen Printing Machine:
Uses higher cost of galvano nickel screens.
Screen changing time longer.
There is also a tendency for carpet to spoil during stoppages(Cause: the paste tends to flow fairly easily through the coarser mesh screen when it is stationary)
The use of thickeners with short flow properties can help prevent leakage from the screens when stopped.
Minimizing dye paste use in rotary screen printers
A water-saving system on the washing machine for the barrels or screens not only reduces water consumption, but also results in a more concentrated waste load. In case the washing process takes place in three stages, in the first stage residual water from the second and third stages is used that was temporarily stored in a recirculation reservoir. The strongly contaminated wastewater resulting from the first stage is discharged to the water treatment system and then to the sewer. In the second stage of the washing process, both the water intake and the water outlet are connected to the recirculation reservoir. Finally, in the third stage of the wash cycle, the barrels or screens are washed with clean water. The residual water resulting from this last stage is then fed into the recirculation reservoir, which is thus replenished. In the recirculation reservoir and on the intake side of the water pumps, filters make sure that pollutants of all sizes are removed from the water, thus preventing blockage of the spraying system. By implementing a water-saving system, the water consumption of a specific machine can be reduced by 80%. A water-saving system is applicable for the cleaning of screens, squeegees and barrels. A water-saving system can be installed on existing machines or a new system can be purchased with an integrated water-saving device. The additional costs compared to washing machines without water-saving is approximately EUR 10 000 for screen washers and EUR 3 000 for barrel washers.
In rotary screen printing, for every colour there is a screen, a supply system for the colour and a paint kitchen inventory. After every printed batch the system has to be cleaned thoroughly. As a result, considerable amounts of dye paste end up in the wastewater, because the volume of the machines is significant and a substantial quantity of dye paste stays behind in the system. Minimisation of the system volume on rotary screen printing machines has become a reality with the introduction of a new pump and squeegee system.
Environmental effect
Usually, the system volume of rotary screen printing machines varies from a few kilograms to maximum 10 kilograms, with an average of 5 kilograms. With the new pump- and squeegee system it has become possible to reduce the system volume per recipe by approximately 60% in comparison with a conventional squeegee system. This means a significant reduction of the use of dye paste. Furthermore the system allows to return a large part of the excess paste into the system. This way 1,5 kilograms of dye paste per pattern can be recycled. A second option to reduce the excess paste and pollution from the rinse water is the use of a rubber ball in the squeegee. After printing, the ball (25 – 30 mm diameter) scrapes the squeegee clean and the excess paste is transported back to the dye kitchen.
Reduction of dye paste emissions and water consumption. The quantity of washed out sludge can be reduced by 5 – 35 % at the overall corporate level. This measure is applicable as a replacement investment for rotary screen printers.
Conclusion
The additional costs are around EUR 50 000 (INR 2 500 000) Savings can be achieved on raw materials and auxiliary materials as well as wastewater charges. Because of the additional costs this measure is especially feasible when the rotary screen printers are being renewed. End of Rotary-Screen Printing Machine article
Industrial Inkjet Printing Machines is a stream of liquid in the form of a dye solution produced by a spray nozzle. It is an innovative method for the application of wonderful patterns to the textile materials whose small droplets of dye solution are ejected and applied to a precise location. It is mainly used to produce pattern on carpet. Average speed =625000 drops/ sec. Design produce by CAD. Read about Digital Inkjet Fabric Printing Machine
Unlimited
color is produced.
0
(zero) waste printing.
Types of Ink-jet Printing:
It is mainly two types.
1. Continuous Ink-jet Printing.
2. Drop-on-Demand (DOD) Ink-jet Printing.
In continuous ink-jet printing the
link is forced at high pressure through a small nozzle of (10-100) micros in
diameter. Thus a continuous stream of dye droplet is format which is directed
onto a substrate. This is achieved at a frequency of 625 KHZ. The droplets are
selectively charged with negative electric charge. There are two application
methods.
Multilevel
application:
Charged drops are used for
printing and unchanged drops mare collected in a catcher. It is possible to
control up to 30 different dot possible per nozzle. The ink is collected in a
catcher and recirculated.
B. Binary Application:
The uncharged drops are used printing
which the charged one are collected by the catcher. Only one dot position per
nozzle is possible. The ink is collected
into catcher and recirculated.
DOD:
Here droplets of color produced by
nozzles that open or closed quickly on command from a computer are fixed into
the substrate passing beneath the nozzles. Here the dye liquor is jacketed by a
suitable electromagnetic valvs.Located in dye liquor feed tube in a pre determined
sequence determined by the pattern to be printed. It is also called chromo
tonic process.
Ink
formation recipe-
Pigment- 2-4%
Binder-10-15%
Additives-1-2%
Fixer-1-2%
Water is required.
Design
is made by-
1. Scanning.
2. Create design in CAD. 3. Directly formatting to digital pattern on machine
Steam Fixation of Prints:
Very considerable energy would have to be expended to dry the carpet (having about 250 pick up of print paste) the steaming time is much reduced when the process is carried out on wet carpet. The first requirement of the steamer is that must be capable of transporting the material through its interior without affecting the quality of goods and without allowing unfixed dye to mark off on to other parts of the print. The second requirement is that the steam quality must be such that dyes are fixed as rapidly as possible, with out any tendency to being or any loss of clarity of print.
Advantage of Ink-jet Printing:
Digital pattern data from CAD system can be used immediately
to drive the printer, hence allowing quick customer response.
There are no screens to handle and there is instantaneous
change of pattern and hence much improve machine occupation making short runs
economically viable for comparison
changing screens on an eight color rotary screen carpet printing machine
takes about 1 hour.
No screen replacement or storage space is required.
No physical pressure is exerted on the carpet pile therefore
optimum surface appearance results.
Large repeats are possible without resorting to special
techniques.
Disadvantage of Ink-jet Printing:
Skill worker need.
Very expensive.
NEW FEATURES • Higly configurable powerful Center Side QC module • Completely new powerful recipe editor • Manual match modification to adjust match results in the results table • Textual and graphical lab recipe history • Impressive and powerful 3-D dyestuff display in color space facilitates dyestuff selection for difficult matches • Manual smartmatch housekeeping with computer aided grouping of similar points supported by exciting 3D graphics • Green tile calibration for improved calibration reliablility • Improved match input dialog allows to measure new substrates directly and simplifies selection of dyesets • Save and restore match parameter settings • Improved stock solution volume calculation reduces liquor amount if necessary
Conclusion
Usage of Industrial Inkjet Printing Machines for stock solution configurable per client. Restricted users can not delete or rename data, can not change important settings
The Peter Zimmer machine operates on the principal of the electro magnetic double roller squeegee. The print paste confined between two rollers which are of a considerably larger diameter (80 mm). Pile penetration by the print paste is achieved by pressure wedge of paste trapped in front of the second roller as it moves forward over the screen. In this machine screens are covered with 60-70 mesh polyester screen fabric. The downward pressure and reciprocating motion of the squeegee roller is achieved by a bank of electromagnetic moving beneath the endless rubber belt that carries the carpet. Maximum running speed is usually 2-4 m/ min, depending on carpet quality.
Principle
The
UV screening agent is applied in combination with TERASIL X dyes by flat screen
direct printing.
The
light fastness improvement achieved for
two dye combinations is assessed colorimetrically by standardized HT light
exposure tests.
Procedure
Material
Tersuisse
polyester tricot,
washed off, heat
set at 175°C
type
2031 (No. 5-4204 )
Machinery
/ apparatus
Zimmer
Mini MDF 305 flat screen printing machine drying oven
Mathis
high temperature steamer
Dyes
Dyes
beige
charcoal
TERASIL
Yellow X-GWL
1.3
g/kg
TERASIL
Red X-GSA
0.3
g/kg
TERASIL
Violet X-B
0.04
g/kg
TERASIL
Blue X-BGE
0.3
g/kg
TERASIL
Grey X-SGN
50 g/kg
Stock
thickening
120 g
Solvitose C5 10 %
480
g Lamitex M5 6 %
380
g de-ionized water
5 g sodium dihydrogen phosphate
10
g sodium chlorate 1:2
5 g LYOPRINT AP
1’000 g
The carpet is transported by means of an endless rubber blanket or rubber strips. It is sometimes carries small pins on the surface to grip the
Four type of rotary screen printer for carpets have been produced namely.
The Peter Zimmer machine with a magnetic roller squeegee friction driven with variable magnetic pressure.
The Peter Zimmer Hydroslot system which relies on hydrostatic pressure to force the paste through a slot in the special squeegee box and into the carpet pile.
The Mitter positively driven roller squeegee which combines the use of large squeegee diameter and high paste levels be hind the roller to achieve good color penetration into the carpet pile. Special flexible screens of triangular cross section can give repeats up to 4 meter.
The Johannes Zimmer Magnojet and Viriojet machine which are a further development of the Hydroslot system.
Tapestry Carpet :
Tapestry Carpet also a handmade carpet. Here wool&
cotton is used. Any kind of design can be done on the surface of Carpet. Human
being, animals, natural beauty, Birds, etc design cane be done this type of
Carpet. Pile height depends on the design object of carpet.
The Fardin Carept is one of the carpets known carpet associations
in Bangladesh. They have different kind show room in Bangladesh. They actually
collect the carpet from Millat Camp.
In Millat
Camp, the Bihari People only made the carpet . They also export the carpet in
Malaysia. Only 4 looms they used.
In
Bangladesh there was another Carpet Manufacture that is “Bengal carpet Ltd.”.
Actually they were the main Carpet manufacturer in Bangladesh. They were stared
a new sensation on carpet manufacturing in Bangladesh and abroad also. Bengal
Carpet was started there journey in 1980.They also exported their in Italy,
Franc, Germany, etc. They made their carpet by Machine loom. They could make
twist , velvet portion carpet ,mat, hang mates. But now they are stopped their
carpet manufacturing. Because the lack of order. They started carpet
manufacturing in a benefits way but day by day they faced in loss of
production. For this reason they stopped their production.
They
stopped their production in 2002.
But now
days they are making mat, braided lace and
But now days they are making mat,
braided lace, and jute rope etc. Now they are thinking to sell their industry.
Another man
who sustain carpet manufacturing in Bangladesh. He is Ali akbor the owner of
“Society handicraft”. He stared his mission from1988. But he organized his
organization from 1990. In 1990 he started his organization with 1 loom. But
now it is standing in 60 looms. Per month he earned 6 to 7 lac taka.
Mainly “Aarrong” is the main suppliers of his organization. Aarrong give
him design and according to their design
Ali akbor make carpet. Ali akbor is a very skill man who can make any kind of design on his carpet.
Society handicraft mainly situated at Nana Genda, in Savar.
Now a day Society Handicrafts played a vital role on Carpet market in Bangladesh.On the other hand in Rangpur district there have some Carpet manufacturer. They also made Carpet, Sotoronji, etc.
Moreover our well known stair carpet runners and carpet
runners collection (still produced in France in one of the only remaining and
genuine Aubusson carpets factory) is now purchased from all over the world and
shipped to thousands of customers from Europe (U.K., France, Belgium, Poland,
Romania, Spain, Switzerland etc…) or from the U.S.A, Far East, Middle East,
Africa etc… Eventually, we have also developed over the last few years a
significant volume of custom made hand tufted wool area rugs and luxurious
handmade hand tufted carpet runners and wall-to-wall carpets business in
partnership with some of the most experienced and skilled Indian and Chinese
companies.
Initially there were two types of types of flat screen-printing machine for carpets namely BDA machine (Manufactured for a time by Single Cobble) and that produced by peter Zimmer. Read about Rotary-Screen Printing Machine
The BDA machined in operation until 1990 but none is still in use. In this machine a reservoir of dye was confined between the blades of a double squeegee passed. To achieve this conventional rubber transport blanket was replaced by an endless belt of perforated metal platens which carried the carpet forward when the screens were lifted after each printing cycle. The screens are covered with (60-70) mesh polyester screen fabric. Despite the relatively low vacuum used (about 75 mm water gauge) it was possible to obtain good penetration on fairly long pile carpets. The maximum speed of the BDA machine is about 5 m/min.
Study on Carpet manufacturing (Machines &unlike dyeing
process) technology first we thought its easy topics for our senior project
work. But when we started our work that time understood what a hard project.
First we wanted to know where carpet is made. We searched the internet and got Bengal Carpet is the only carpet manufacturer in Bangladesh. First we went their corporate office in 37 Kamal Ataturk Aavenue, Banani-Dhaka-1213. Then our honorable course instructor gave us a forwarding letter to Bengal carpet for 10days thesis work. But after 15 days later there was no Bengal carpet office. That time we were disappointed about our project work. Then we told about Bengal carpet to our honorable Instructor . Then she tried to search about the Carpet manufacturing company in Bangladesh. Then she told us to go carpet show rooms at Elephant road in New market. Then we went new market and tried to search about Carpet manufacturers in Bangladesh. Then we understood Carpet were the only Carpet Importers in Bangladesh. They told us there is no Carpet manufacturer in Bangladesh. We also disappointed about our Project work.
Bengal carpet was one of the Carpet manufacturers in
Bangladesh. is company produced different types pf Carpet & gives them different
printing effect. In Millat camp and Society handicrafts also produced different
types of carpet in Bangladesh.
But now a day’s carpet demand decreasing day by day.
Most of the people in our country live in under poverty
level and they have no enough idea about carpet. Because 85% of them depends on
agriculture and 15% of them depends on Job, business etc. In Bangladesh more
than 50% people are supporting their live by hand to mouth system.. So in 15%
people only 8% are very rich. So its easy to understand what would be the
carpet market in Bangladesh.
So demand of the carpet for Bangladeshi people is not
mandatory with their life. Few people in a city who are using carpet in hotels,
show rooms and also using house for decorative purposes. On the other hand they
wanted to use carpet in winter.
I f a country 10 people were consumer a product so what will
be the demand & market of this product?
