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
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?
There are different types of digital textile printing machine and garment printing machine is manufactured by the companies. Example of some machines are – Block Printing Machine, Roller Printing Machine, Screen Printing Machine, Flat-Screen Printing Machine, Rotary Printing Machine, Transfer Printing Machine, Stencil Printing Machine, Digital Printing Machine, Batik Printing Machine etc.
Marking is done on printing machine bed for correct and accurate placement. Cut parts are placed on the m/c bed and screen is placed on top of cut parts.Prepared emulsion in form of paste is poured over the screen and is squeezed with help of roller or squeegee. Emulsion passes through screen and is fixed on the cut parts thus printing is done on cut parts.
Hand Curing : After printing when cut parts are removed from machine Manual hand curing is done with the help of a dryer. This is done to dry the print so that it does not spread out.
Machine Curing: Temperature and run time of curing machine is adjusted according to nature of fabric Then cut parts are placed on the conveyer belt of curing machine and is passed through thus the print is completely dried up and printing is over.
Pilot Run and Bulk Production: After Order confirmation Bulk Production starts on planned date. Work stations are defined samples and mock-ups are kept for reference. Hourly Targets are given by IE dept at the time of Bulk Production. Same printing recipe is used which was developed at sampling stage.
The first 50 pcs are the pilot run samples which after sewing are sent for washing and after wash garments are reviewed. If after wash print quality is not ok then modification is done in recipe and recipe is finalized accordingly and we proceed with bulk production.
Quality Assurance: Approved Mock-ups are visually displayed in printing dept for reference. Marking is done on digital textile printing machine for correct print placement.Operators are being trained by supervisors and technicians. Operators have also been trained for self checking the pcs to ensure 100% quality. Recipe is written into local language Bangla which is best understood by the Supervisors and Operators.
Supplies Responsibilities:
Color: If colors are chosen from suppliers color palate, no lab dips are required. If colors are chosen from pantone, scotdic or another source, lab dips are submitted to customer following color approval procedure.
Testing: The Supplier must test blanks of all styles and all colors, following customer performance testing requirements. Note: If the same color/same style was used in a previous season , the supplier must have the color/ same style was used in a previous season, the supplier must have the style/ color retested. An exception would be an ongoing, uninterrupted program. In case, only new colors must be submitted for approval. Testing of all blanks is required on a yearly basis, following standard testing procedure.Bulk fabric should be sewn into approved style in supplier sample room and submitted for testing, prior to shipping to sewing factory.Submit to intertek testing under protocol 12- Garment testing, following the minimum sample requirements for the garment testing and additional color testing.
QA Audits : Perform the CWIQ evaluation on all colors. Conduct a Final cutting QC on all styles/shipments. This is including the measurement portion of the audit, following supplier spec sheet.
Vendor responsibilities : Conduct pre-production meeting to review the approved sample requirements, screen placement and any other customer requirement. Confirm all the colors match approved bilk sample garment, following customers colour approval procedure. Confirm main label and care label are correct as ordered.
During production : In-line inspection of all the operations being performed. Opportunity to identify any machinery, operator, construction, workmanship or measurement issues and immediately correct. PTL sample is pulled and sent to Technical designer.
CWIQ Evaluation: Perform CWIQ evaluation on all colors and all screen prints. This should be completed during 1st print run per color.
Final Random Inspection: Conduct final random inspection(FRI), including both measurement and workmanship audit. The measurement portion of the audit is required, due to heat being applied during the printing process. Supplier spec should be followed for this audit.Sampling plan to be used for both the workmanship and measurement audit is based upon single sampling/S-4/Reduced, per color and for all purchase orders, regardless of size. 13 piece sample size, reject at 4.
Customer responsibilities: Customer will verify all the styles have a passed intertek test report by season , noting the exception indicated above.Customer may select styles/purchase orders to be inspected our 3rd party. Factory inspection procedure.
Advantages of Block TextilePrinting Machine Works
Simple method of printing
No expensive equipment required
No limitation in repeat of size of style
Prints produced have great decorative value and stamp of craftsmanship
Digital Textile Bolck Printing
Disadvantages of Block TextilePrinting Machine Works
Involves much manual work
Method is slow and therefore low output
Good skilled labors needed for multi color design
Fine and delicate designs hard to produce
Advantages of Roller Printing Machine Works
Large quantities of fabric at the rate of 914-3658m per hour can be printed.
Faulty joints or joint marks are absent.
Fine sharp outlines and good prints can be obtained which is difficult to get in block printing.
Disadvantages of Roller Printing Machine Works
Not economical for short run of fabrics.
Difficult to produce blotch designs.
Repeat of design limited to the size of the rollers.
Setup cost of roller printing m/c is high
Advantages of Stencil Printing Machine Works
Simple and cost effective.
Stencils can be made rapidly and can be used for small orders.
