yarn and carpet printing

TE 362 PRINTING TECHNOLOGY YARN AND CARPET PRINTING

Group 5

Submitted by : FURKAN KETENCİ

AYBALA ÖZCAN

ŞİLAN BOZKUR

BARAN BOZKUR

04.05.2012

Submitted to : Ass.Prof.Mehmet DASDEMIR

INTRODUCTION

• This project includes processes, techniques and datas of yarn and carpet printing technologies.

• First part of the project includes yarn printing techniques and their compares between each other.

• Second part of the project includes carpet printing techniques,used chemicals and processess.

YARN PRINTING

• Yarn printing is the special type of printing process.

• Yarns are dyed in package form or hank form by yarn dyeing process.

• It is slighlty difference from woven or knit printing for the purpose of producing certain decorative patterns in weaving.

• Extruded synthetic yarn from a colored solution; the filament is impregnated with pigment.

Solution Dyed Yarn

• Carpet yarns are wound onto a skein or put as a cone into a kind of dye beck.

Hang,Skein or Package Dyeing

• Process whereby different colors are “printed” along the length of the yarn before it is manufactured into carpet.

Space Dyeing

Yarn Dyeing Types and Properties

Process

Yarn Dyeing Types and Properties

Space Dyeing• Space dyed carpet is a yarn dyeing

process in which different colors are applied along a length of yarn at intervals.

• Space dyed yarn produces, in its subsequent tufted fabric form, an effect of random,unorganized design and multi-colored.

• Space dyed yarn is sometimes referred to as dip dyed yarn.

Space Dyeing

• Spaced dyed yarn is most commonly used for knitting and crocheting.

• When space dyed yarn is made to make a knitted or crocheted item, the resulting project features uneven horizontal stripes that produce a collage-like effect.

• Two space printing methods are available which are knit-de-knit and warp printing methods.

Types of Space Printing Process LineKnit-de-knit

Printing

Dyeing & Printing

Steaming

Washing Extracting

Drying

Warp Printing

Dyeing & Printing

Warping

Tufting

Steaming

Washing

Drying

Multi Colored Yarn Dyeing• The secret to space dyeing

yarn involves the use of a special chemical called a mordant.

• The purpose of a mordant is to help permanently fix the dye to the yarn after the space dyeing. This makes it possible to dye the same skein of yarn many different colors.

Multi Colored Yarn Dyeing System Properties• Cylindrical machines, the printing system has felt and

mechanical shears.

• Dye transfer printing process rollers and felt each other through the cylinder pressure is performed.

• Mechanical pressure system and synchronized with

scissors quiet study have been provided with the pattern of change during the time loss is prevented.

yarn printing machine - YouTube.flv

CARPET PRINTING

• The initial development of the printing of carpet in the UK after the introduction of tufted carpet production, which followed the in the USA from the early 1950s on wards.

Methods of carpet printing

Direct printing

Discharge printing

Resist printing

Pigment printing

Methods of carpet printing

Direct printing

Discharge printing

Resist printing

Pigment printing

1-Direct Printing

• Direct printing is a white fabric or directly on the pre-dyed fabric printing. The latter is called overprinting.

• The complete pattern including the base color.

• In screen printing the base color can also be applied with a padder.

Direct Printing

Advantage

Simple method

Disadvantage

In screen printing only dark colors on light shade

Process of Chromojet Direct Printing

Padder - for pre wetting of high pile carpetGum Applicator for shading effectsDye Applicator for the base colorPrinting Machines for accent colors and designs

Padder

Chromojet Direct Printing Machine

Methods of carpet printing

Direct printing

Discharge printing

Resist printing

Pigment printing

2-Discharge Printing

• Discharge printing is characterized by a dark ground shade highlighted by light and bright printed.

• This makes the carpet look more attractive.

• The condition for performing the displacement technique is the use of dyestuffs with different affinity to polyamide and cationic resist agent.

Discharge Printing Methods:

• Discharge printing can be done in two ways:

• the fabric piece dyed color• Using a padder for the ground

shade and printer to overprint1st way

• the pattern printed on the fabric.• Printing the spot colors and over

dyeing with a dye applicator after printing. This is the common method.

2nd way

Discharge Printing

• Discharge printing is common with screen printing to overcome the problem of low penetration of printed colors.

Advantage

High penetration value

Disadvantage

High water usage

Schematic Representation Of Discharge Printing

Methods of carpet printing

Direct printing

Displacement printing

Resist printing

Pigment printing

3-Resist Printing

• Resist printing ,including a two-stage process

• printed on white fabric can stop or prevent dye penetration into the fabric of chemical agents or waxy resin.

1st Step

• piece-dyed fabrics. Its purpose is to dye the white background to bring out the pattern.2nd Step

Quick Change of Resist Printing • The advantage of this process is that printing can be

done in large runs and the base colour can be done at a later stage in short runs by winch or continuous using an overflow applicator ( Quick Change).

Best definition of color separation of prints

Advantage

Long process, high cost

Disadvantage

Methods of carpet printing

Direct printing

Displacement printing

Resist printing

Pigment printing

4-Pigment Printing• Paint pigment printing is direct printing, the printing

process is often called dry method, as distinct from wet printing.

• Pigment printing is the printing production of the most inexpensive way of printing.

• The printing is relatively simple because the coating, the process required at least, usually does not require steaming and washing

PRINTING MACHINES

• Nowadays,printing industry develops rapidly and new technology adds new equipments and systems on this printing machines.

• Here are the most commonly used carpet printing machines in textile industry ;

-flat-screen printing machine -rotary-screen printing machine -spray and jet printing machines

Flat-Screen Printing MachineFlat-screen printing machines can be manual, semi-automatic or completely automatic. One type of machine, which is still commonly found in printing houses, can be described as follows. The fabric is first glued to a moving endless belt. A stationary screen at the front of the machine, is lowered onto the area that has to be printed and the printing paste is wiped with a squeegee.

Flat-Screen Printing Machine Process

The printed fabric moves forward step by step and passes through a dryer. The machine prints only one color at a time. When the first color is printed on the whole length of the fabric, the dried fabric is ready for the second cycle and so on until the pattern is completed.

Rotary Screen Printing Machine

ROTARY SCREENS

PRINT PASTE SUPPLY

PRINTED CARPET

PASTE FEEDING MECHANISM

A combination of roller and screen printing in which a perforated cylindrical screen isused to apply color. Color is forced from the interior of the screen onto the cloth.

Schematic Figure Of Rotary Screen Printing Machine

Spray and Jet Printing Machines

• Jet printing is a non-contact application system originally developed for printing carpets.

• This system can be likened to an injection dyeing process.

• Spray printing systems and first generation jet printing methods cannot be controlled to produce a pre-specified pattern.

Jet Printing Machine

Process of Jet Printing

Chemicals For Carpet Printing

Antifoams to avoid foaming

Penetration and Leveling Agents to control pH variations

Resist Chemicals for resist printing

Preservation Chemicals to avoid bacteria and fungus

Acid Donors to achieve a lower pH

Retarding Chemicals to avoid that the dye is fixed

Chemicals For Carpet Printing

Dispersing and Leveling Agents affinity to fiber, affinity to dyestuff

Wetting Agents to improve penetration of prints

Anti-frosting Agents to avoid frosting

Carriers for disperse dyeing of Polyester carpets

Flame Retardants or Other Finishing Products

to avoid combustibility of fabric

Foaming Agents for foam finishes

CONCLUSION

• In this project,we explain carpet and yarn printing technology;

Yarn printing methods and typesCarpet printing methods,machines and chemical

agents• We support the our presentation with multimedia

and schematic figures and photos.• Nowadays,carpet printing does not widely use in

our country because of inadequate printing suppliers in textile industry.

REFERENCES

1- http://www.floorbiz.com/carpet/carpet-buying-guide/dye-methods/space-dyeing.html

2- http://www.wisegeek.com/what-is-space-dyeing.html3- http://www.floorpromotion.se/en/technology.html4- http://chinalogomats.com/Article/119.html5- http://www.zimmer-austria.com J.Zimmer Maschinanbau

GmbH Kufstein6- http://www.ineris.fr/ippc/sites/default/interactive/bref_text/

breftext/anglais/bref/BREF_tex_gb10.html

THANKS FOR YOUR

ATTENTION