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Ink Jet Printing of Textiles

What you need What you need to know but were to know but were afraid to ask ! afraid to ask !

January 2014 1Dr. Sanjiv Kamat

KITL

Language has changedLanguage has changed

LIFE WASMUCH EASIER WHEN Apple AND BlackBerryWERE JUST

FRUITS October 2013 2Dr. Sanjiv Kamat

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And (Terms you would use in IJP)And (Terms you would use in IJP)

• NIPNIP Sip of Liquor or pinch Sip of Liquor or pinch

• RIPRIP Rest In PeaceRest In Peace

• DODDOD Ball on which no run is scoredBall on which no run is scored

• PZTPZT Brother of R2D2, K9 of Star warsBrother of R2D2, K9 of Star wars

• pLpL Privilege LeavePrivilege Leave

October 2013 3Dr. Sanjiv Kamat

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The Digital AdvantageThe Digital Advantage

• Advantages• No minimums• On demand

manufacturing• Efficient sampling• No repeat size• No limit on colors• No color kitchen• No screen engraving• No screen warehousing• No limit on design size• Flexible design

possibilities• Reduced waste• Reduced manpower• Environmentally Friendly

• Disappearing Disadvantages• Speed• Cost• Replication of screen prints


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Historical TimelineHistorical Timeline

1749First research on ink jet in FranceFirst research on ink jet in France

1878Rayleigh-Mechanism of liquid stream in dropletsRayleigh-Mechanism of liquid stream in droplets

1930Ink jet for e recording deviceInk jet for e recording device

1951Siemens “Elema” first commercial ink jet m/cSiemens “Elema” first commercial ink jet m/c

1967Stork produces high colour images by ink jetStork produces high colour images by ink jet

1970Piezo and thermal DOD, Printing of carpets, Milliken/ZimmerPiezo and thermal DOD, Printing of carpets, Milliken/Zimmer

1991first commercial system at ITMA Hanoverfirst commercial system at ITMA Hanover

2000 Cannon developed high resolution Printer

Encad Introduced Textile Printer/Iris

Modified Mimaki’s Introduced

Stork/Dupont /Yuhan Kimberly, Reggiani and Robustelli Machine

2010Osiris Machine

2011Kyocera Print Head Machines

2013MS Lario


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The Essential ElementsThe Essential Elements

• Print headPrint head

• Fabric Feed System/ PrinterFabric Feed System/ Printer

• InkInk

• FabricFabric

•SoftwareSoftware

•Pre/post treatmentPre/post treatmentJanuary 2014 6Dr. Sanjiv Kamat

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Understanding the technology involvedUnderstanding the technology involved

Courtesy: Dr John Provost


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•Thermal Drop on Demand(DOD)

•Piezo Drop on Demand

•Binary Continuous inkjet heads

•Multi-deflection continuous heads

•Air jet deflection

Printhead TechnologyPrinthead Technology


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KITLInk jet Technologies- A Summary•Continuous (CIJ) = continuous flow of ink –Method to produce drops –Method to select drops –Method to recover and control the ink •High speed capability •Typically low resolution, but high resolution capable •Drop On Demand (DOD) = drop of ink only generated when needed –No drop selection or deflection required –Each nozzle fires only as required – nozzles can be inactive •Nozzle maintenance and good ink formulation required –Actuation mechanism required with enough energy to generate drop at required velocity to eject and reach substrate successfully •Actuation methods – most common are thermal and piezo –Piezo dominant technology in textile printers

• Most common is lead zirconium titanate(PZT) ceramic

• Electrical pulse causes the material to “Push” “Bend” “Shear”

•

Piezo Print headPiezo Print head


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KITL• Piezoelectric ceramic material deforms when voltage is applied

•Distortion creates a pressure pulse in the ink chamber

•Causes a drop to be ejected from the nozzle

•Many different modes – shear, bend, push, edge = different configurations of the piezo material and the nozzle

Piezo functioning


KITLWhy Piezo drop on demand

•Robust technology for broad range of industrial applications

–Proven in production •Adaptable configurations to provide higher speeds and print quality •Consistent drop velocity and drop volume •Wide range of ink capability

–Enables wide range of applications •High accuracy jetting •Long life printheads

–Capable of high duty production –High reliability (subject to correct use)


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•Binary –One drop size –On or off •Multi-pulse binary –Special mode offered by some printheads –Ability to create larger drops (all same size) •Greyscale –Variable number of drops •Drops coalesce in flight or at nozzle plate –Directly vary drop volume •Vary waveform according to drop size required •Apply different waveforms to each bank of piezo


KITLGreyscale Printing


KITLResolutionIn digital photography it is the number of dots per inch(pixels). Higher resolution gives higher quality.

In digital printing, printhead resolution is fixed value, given by the number of nozzles per inch. Higher number of nozzles per inch gives higher quality


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• Quality is driven by the printing head native resolution (The higher ,the better)

• Quality depends on the drop-size (The smaller the better.)

• Quality is strictly related to the landing precision (Accuracy angle in landing)

Resolution and Quality


KITLResolution and Firing Frequency

Frequency is the number of drops ejected per second

A Firing frequency is 20.000 Hertz means that each nozzle can jet 20,000 drops per second

Higher the space between drops in the scan direction gives less ink per inch, which means more speed.


KITLInk Flow• End shooter/single ended

•Ink flows into the channel and exits only through the nozzle

•Recirculating/through flow •Ink flows continuously through the channel and exits the nozzle only when required

•Output speed

•Fabric penetration, image resolution

•Ink Chemistry

•Replacement cost and ink costs

•Reliability and Consistency

Printhead Selection based onPrinthead Selection based on


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Printhead TechnologyPrinthead Technology

Kyocera KJ4 2656 nozzles

Epson DX 7 1440 nozzles

Konica Minolta 1024

Ricoh

Epson

Xaar

Kyocera

Spectra

Konica Minolta

Fuji Diamatix

HP Scitex

Sieco Printek


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•The technology is breathtaking-The drops and the nozzles are tiny! A Kyocera KJ4B 30kHz printhead has 2,656 nozzles –Each nozzle can jet up to 30,000 drops/sec–That is potentially a total of 79,680,000 drops per second –On a printer with 8 heads (one per colour) that’s 637,440,000 drops/sec

Taking care of your Printhead


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•Nozzle maintenance is essential – features built into your printer as standard –Manual/automatic maintenance cycles –Spitting –Purging –Capping –Wiping (dry and wet) •Drop formation is very sensitive to ink properties and nozzle condition •Discuss maintenance with your system provider –Comprehensive maintenance systems can have a huge effect on printhead life and replacement costs

Nozzle Maintenance

PrintersPrinters

Printer Classification

Class 14-12 metres per hour



Class 465-75 metres per minute

Key FeaturesKey Features

Ability to transport wide variety of fabrics through printer

Able to deliver variety of textile ink chemistries through print head

Either open or closed system for ink and software

Mutoh

Zimmer

Mimaki

D-Gen

Roland

HP /Agfa

Konica Minolta

MS

La Meccanica

Reggiani

Digitex

Osiris

Ichinose

Kornit


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Print methodsPrint methods


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KITLScannnig XY•One pass printing –High productivity •Multipass printing –Passing two or more times over the same line of image data –Typically 2 different nozzles print on the same line Global


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Fixed array of printheads –High productivity –Established in many other industrial applications (ceramics, labelling etc) –Emerging in textile –Reliability critical

Single Pass Printing

Printing MachinesPrinting Machines

ReggianiIchinose

Digitex


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Printing MachinesPrinting Machines

MS-LARIOIndustrial print head 4-8 colorsFixed array configurationSticky-Belt fabric transportPrint speeds up to 75 SM per minute


Regianni has now a machine at 120mt/min

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Kornit Avalanche T shirt printingKornit Avalanche T shirt printing

300 T shirts per hour size XXL 60x90 cm, CMYKW


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Ink Color Gamut (CMYK)Ink Color Gamut (CMYK)

Black• Lemon Yellow(Y)• Golden Yellow• Bright Orange• Mid Red• Neutral Magenta(M)• Neutral cyan(C)• Bright Reddish Blue• Black(K)


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October 2013 31Dr. Sanjiv Kamat

KITLLimitations of Colour Space

InksInks

• Fabric dependent inks

• Acid dye• Reactive Dye

• Dispersed Dye

• Sublimation $

• Fabric independent ink

• Pigment

• Eco-solvent• Latex• UV Cure

Huntsman

Dystar

Jaysynth

Fuji Sericol

DuPont

Solaris/ Jay Chemicals

Sawgrass

Nazdar


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• High Purity

• High Solubility

• Rheology properties of solution

• Particle size and distribution

• Conductivity

• Surface charge and polarity

• Foaming properties

• pH

Requirements of ColorantsRequirements of Colorants


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Typical Ink FormulationTypical Ink Formulation

• 3-6% dye• 70-80% water• 20-25% Humectant(DEG/2-Pyrrolidone)• Surfactant (perflouro based)• Penetrating agent (Hexane-1,6 diol)• Preservative (methyl-isothiazolones)• Corrosion Inhibitors (Benzothiazoles)• Electrically conducting Lithium salts

Viscosity ~1-3 centipoiseSurface Tension ~ 35 dynes per cm

Januray 2014 34Dr. Sanjiv Kamat

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•Printhead analysis –Materials compatibility

•Dye purification

•Formulation development

•Drop analysis

•Accelerated shelf life tests

Ink Development


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•Dye synthesis and purification •Raw materials - high precision weight scale

•Purified powder dye mixing in glove box

•Ink mixing – different batch volumes

•High precision filtering

•Degassing (cartridges)

Ink Production

Digital Textile Ink Characteristics

Ink Fabric Type Pre-treatment Post Treatment

Acid Dye Nylon, Silk, Wool

Yes Steam Heat

Reactive Dye Cotton, Rayon, Silk

Yes Steam Heat

Dispersed Dye Polyester Yes (usually) Steam or Dry Heat

Dispersed Sublimation

Polyester No Dry Heat Transfer

Pigment Most Types No (usually) Dry Heat


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FabricsFabrics

• Most fabrics can be printed digitally with proper pre-treatment and fixation

Cotton

Polyester

Rayon

Nylon

Wool

Viscose

Linen

Acrylic

Nonwovens


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Raster Image Processor (RIP)Raster Image Processor (RIP)

In computer graphics, a raster graphics image, or bitmap, is a dot matrix data structure representing a generally rectangular grid of pixels, or points of color, viewable via a monitor, paper, or other display medium. Raster images are stored in image files with varying formatsJanuary 2014 39Dr. Sanjiv Kamat

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http://en.wikipedia.org/wiki/Computer_graphics

http://en.wikipedia.org/wiki/Dot_matrix

http://en.wikipedia.org/wiki/Data_structure

http://en.wikipedia.org/wiki/Rectangle

http://en.wikipedia.org/wiki/Pixel

http://en.wikipedia.org/wiki/Color

http://en.wikipedia.org/wiki/Computer_display

http://en.wikipedia.org/wiki/Paper

http://en.wikipedia.org/wiki/Image_file

Software - Software - All RIPS are not created equalAll RIPS are not created equal

• Features of a textile RIP1. Color management

2. Workflow

3. Cost analysis

4. Optimum resolution

5. Drop size management

Wasatch

Ergosoft

DP innovations

Caldera

DGS

Inedit

Cheran Digital


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• Takes the digital image and converting the image data, to a sequence of codes that control the printer firing the nozzles and moving the head and media.• Includes printer driver(s) technology which is responsible for ensuring the correct code sequence is sent to the printer.• Requires color management technology. Color management technology typically requires a profile.

What exactly is RIP


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Basically a colour matching program• Each piece of data is a printer ink formula with a measured color value•The printer ink formula is a percentage mixture of the inks in the printer•The RIP sends an image color value to a color management engine, which uses the profile, to obtain what printer ink formula should be used to print that color

What is a Profiler

Overview of segmentsOverview of segments

Colorant Ink Type

Ink Types Fibre Market Applications

Pre / Post treatments

Reactive Aqueous Cellulose, wool, silk Apparel Fixation + wash

Acid Aqueous Wool,silk,nylon Apparel, swim wear

Fixation + Wash

Disperse Sublimation(LS)

Dispersion Polyester Paper for Flag banner, sports wear, signage,

Heat Transfer

Disperse Sublimation, specific types(MS)

Dispersion Polyester Signage Pre Treatment and heat Fixation

Disperse direct(HS)

Dispersion Polyester Apparel, Automotive

Pre treatment, heat Fixation, wash

Pigment Dispersion Cellulosic+ all possible

T shirts, Home furnishing, bed linen, flags, drapes, banners, children wear

Heat Fixation – with DTG also Pre Treatment


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• Constant dot size and formConstant dot size and form

• Better levelnessBetter levelness

• Good colour yieldGood colour yield

• Better image qualityBetter image quality

Pretreatment of textiles to ensure


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Typical Pretreatment recipe ReactiveTypical Pretreatment recipe Reactive

Pad (80-90% Expression) Sodium Alginate solution 100-150gmUrea 50-100gOxidising Agent 10gSodium Bicarbonate 25gWater 1000g(For Viscose increase Urea to 200g)

Dry Temperature below 120deg.C

Inkjet print Reactive

Fixation Atmospheric steaming 8min at 102 deg.CBake Fixation 6-8min at130 deg.CFor heat fixation(not for viscose) use 25 g/kg sodium carbonate

Was off Cold water rinse(overflow)Rinse in boiling water.Soap at boil,cold water rinse

Dry


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Typical Pretreatment recipe DisperseTypical Pretreatment recipe Disperse

Pad (80-90% Expression) Sodium Alginate solution 100-150gCitric Acid 2gDefoamer 0.2gWater 1000g

Drying not to exceed 100 deg.C

Inkjet Print Inkjet print with disperse dye inkjet ink

Fixation(temp/duration depends on disperse-dye inkjet used)

HT steam(180 deg. C for 6-8min)

Wash off Rinse with cold water, reduction clear, hot soap, rinse hot water, cold water rinse

Dry


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FinishingFinishing

• Finishing Characteristics• Dry heat fixation for pigment, latex,

dispersed and sublimation• Moist heat (steam) for acid and

reactive• Atmospheric or pressurized steaming• Washing after fixation• Drying after washing

Practix

Setema

Kleverik

AIT

MS

Monti Antonio


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Heat Press – Steamer -- WashersHeat Press – Steamer -- Washers

What do these machines look like?


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KITLProblems due to•Bubbles –Caused by leaks in ink supply system –Inks not properly degassed –Ingestion through the nozzle –Can be averted by; •Good degassing •Ink supply that avoids bubble traps •Jetting –Satellites, microspray during jetting –Drops with low velocity will move with airflow –Jets can generate air currents •No Jetting –Idle (non-firing) nozzles can collect debris •Vibration –Can cause ink to weep onto nozzle plate


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• Low humidity reduces ink flow performance.

• Low temperature(<15 deg. C) affects stability of Acid inks.

• High temperature (>30 deg. C) supports hydrolysis of Reactive inks.

• Dust and high temperature lead to print head blockage

Issues related to Inks


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•Substrate –Dust, fibres, debris

•Blocks nozzles •Semi-blocking nozzles causing drop deviation •Can cause scratches during maintenance and

so cause drop deviation •Misplaced or missing jets

•Flooding –Can be caused by dust on the nozzle plate, dried

ink and/or poor ink pressure –Excess ink spreads sideways to neighboring nozzles –Excessive ink causes drops to slow down

Issues related to Inks


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Analogue vs Ink Jet printingAnalogue vs Ink Jet printing


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Comparison of the Print ProcessComparison of the Print Process


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How Green is the processHow Green is the process


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Where is it used today ?Where is it used today ?

• Digital Signage decoration dominated by sublimation onto polyester

• Industrial/ Architecture utilizes mainly synthetic wovens and nonwovens with some nylon and cotton. Carpets, technical textiles, industrial graphics (truck covers,hoardings)

• Flags utilizes nylon and polyester with acid dyes or dispersed

• Apparel utilizes a wide range of fabrics from nylon, wool and silk with acid dyes to polyesters with dispersed, to natural fibers with reactive dyes and pigments

• Home Furnishing utilizes cotton , linen and polyester

Sales

Signage IndustrialFlag ApparelHomefurnishing


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Printed Textile MarketPrinted Textile Market

ProductionCurrent production of printed textiles in

range of 27B yards growing at 3%/year

Digital ProductionPortion that is currently digitally printed

around 200M yards

MarketsApparel accounts for 55% of total, Home

Furnishings about 25%, remaining 20% sold into markets such as signage and industrial/architectural.

AdoptionCertain regions and markets have

adopted digital printing more significantly such as Europe, Brazil, and India.

Less than 1% is digital, but headed to 3%. By 2014 it is expected to be 14%


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Kothari Info Tech LimitedKothari Info Tech Limited


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Since 2001, from Surat, India to provide Solutions for Digital Printing on various substrates

Inks Division: Inks Division: Water based high density Charu™Charu™ inks and Disha™Disha™ pre-coatings for Textile substrates(Cotton ,Viscose, Linen, Silk, Wool, Nylon and Polyester)

Textile Machinery Division: Textile Machinery Division: Sales and after sales service for “Ichinose” “Ichinose” printing machines““Rimslow” Rimslow” Loopager for Inkjet textile printing. “DTG Digital” “DTG Digital” for garment printing. “DigiEye” “DigiEye” for non contact colour measurement and QC

Software: Software: Print Pro™, Print Pro™, world class software, for Colour Separation, Colour Correction, Device calibration, Half-toning, Large image data handling, Digital Imaging, Textile coloration, Image composing and Printing. These applications are targeted towards , label printing as well as Wide/Large format digital printing for graphic arts, photography, and Textiles(fabric and garments).

I hope I was able to address your fears and make you comfortable with Ink Jet Printing of Textiles?


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KITLCotton Art-Transfer printing of Natural fabrics- German Dutch


KITLAcknowledgments for some of the visuals

Numerous web sources for diagrams and images like

www.wtin.com,www.pivotal.co.uk, www.imieurope.com www.spgprints.com, www.imaging.org, www.fujifilm.com, www.epson.co.jp, www.konicaminolta.com,www.global.kyocera.com, www.rpsa.ricoh.com, www.siiprintek.co.jp, www.msitaly.com, Ink Jet Forum India

http://www.imaging.org/

http://www.global.kyocera.com/

http://www.rpsa.ricoh.com/

http://www.msitaly.com/