carpet printing - · pdf filezimmer’s history of carpet printing 1. carpet manufacturing...

CARPET PRINTING

Everything you alwayswanted to know

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J. Zimmer Maschinenbau GmbH Kufstein

Eibergstrasse 2-8A-6330 Kufstein/AustriaT ++43 5372 64893F ++43 5372 [email protected]

First edition, October 2003Editor: Tony Naschberger, KufsteinLayout by: SKYWALK Design, KufsteinPrinted by: Druckerei Aschenbrenner, Kufstein

Copyright

© 2003. All rights reserved. No part of this

publication may be reproduced, stored in a

retrieval system, or transmitted in any form or

by any means, electronic, mechanical, photo-

copying, recording or otherwise, without the

prior written consent of Zimmer

Maschinenbau GmbH, Kufstein (Austria).

Trademarks

In this book trademarks have been used which

may be registered in some jurisdictions

and which are owned by their respective

owners. All these trademarks have been used

for informational purposes only.

Zimmer’s History of Carpet Printing

1. Carpet Manufacturing

2. Water, Thickeners, Dyes and Chemicals

3. Dyeing and Printing Methods

4. Print Lines - Machines and Elements

5. ChromoJet - The Carpet Jet Printing System

6. Printing Systems

7. ChromoJet-F - Speed and Flexibility

8. RotaScreen - Carpet Screen Printing

9. Sample and Lab Equipment

10. SupraMix - Dosing and Mixing

11. Color Preparation for Dyeing and Printing

12.Research & Development, ManufacturingLocal Service, Customer Service, Leisure

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Zimmer's history in building textile and carpet printing machines goes back t0 1874 when FranzZimmer began to design and build machines for the growing textile industry. Activities in the car-pet industry started in the early sixties and nowadays this is a major part of Zimmer's business.

Flat-Screen PrinterThe first flat screen printer forcarpet – the legendary TDA62 -was developed by PeterZimmer and put into operationin 1962 at Barwick, Lafayette,

Georgia, USA. This machine was for a longtime the workhorse of the indu-stry. Still today some of thesemachines are in operation.

Rotary PrinterThis type of printer broughtproduction costs down on thelong runs. Speeds up to 30 mper minute is possible andnowadays most of printed car-

pet is produced on screenprinting machines. The firstrotary printer for the carpetindustry was shipped to theUSA in 1969.

ChromoTronicIn the 70's another importanttechnological development byZimmer arrived: the Chromo-Tronic Carpet Printing Machine.For the first time, computercontrolled jets – not traditionalscreens – were used to print apattern.

This was the first digital jetprinter from Zimmer. Threeunits were in operation. Theproblem at this time was thecomputer control but also thechemistry and other compo-nents were not ready yet. Theunit was ahead of its time.

ChromoJetChromoJet was developed andbrought to its success underJohannes Zimmer. The basicconcept was taken from theChromoTronic, but a number ofimprovements and new techno-logies were implemented.Since the beginning of the 80'sChromojet is constantly deve-

loped further and improvedand more than 300 units havebeen sold since then. ChromoJet is now the numberone production method forindividual carpet worldwide. Digital printing has a greatfuture in the carpet and textilemarket.

This brochure is intended to give you a picture and overview of

our concepts and components for the carpet printing industry.

Furthermore it should also furnish some useful information and

an overview of the carpet manufacturing process.

Zimmer as one of the most creative and innovative companies

in the field of printing would also like to be your partner for

new technologies and processes.

Tony Naschberger, Carpet Printing Systems Manager

Zimmer’s History of Carpet Printing

© www.zimmer-austria.com


POLYMER EXTRUSION

STAPLE FIBER

SPINNING

BCF(BULKED

CONTINUOUS

FILAMENT)

HEAT-SETTING SPACE DYEINGAIR

ENTANGLING

TUFTING

PRINTING

STEAMING WASHING DRYING

BACKING SHEARING STORAGE

DYEING

From Polymer

to Carpet


1.1 Carpet Fibers The material for the fiber is selected according tothe application of the product.

Comments Polyamide WoolNylon

Resilience - Determined by fiber structure and modifications.

Good to excellent Excellent

Abrasion Resistance -

Excellent Good to excellentDetermined by fiber and density of face fiber - the more tightlypacked the yarns, the more resistant to wear.

Soil & Stain Resistance/Cleanability

Determined by color, texture, dyes, Good to excellent Good to excellent

fiber structure and modifications.

Resistance to Sunlight - Good - Poor - If protected fromDetermined by fiber special dyes ultraviolet rays, structure and may be used to degradation does not modifications. inhibit sun damage. occur as rapidly.

Static - Determined by Builds up in low Builds up in lowfiber structure and humidity unless humidity unlessmodification. modified. modified.

TouchVaries from warm and

Warm, softsoft to cold and coarse.

Resistance to Mildew - Determined Excellent

Poor if damp or soiled.by fiber structure and modifications. Fiber may be modified

Flammability - Burns slowly, melts;Determined by fiber in direct flame; Burns slowly; structure, modification, self-extinguishing. indirect flame; construction methods, Structure may alter considered dyes, padding and what occurs. self-extinguishing.installation methods. Celery-like odor. Burning hair odor.

Dyestuff groupAcid, metal-complex; Acid, metal-complex and

selected reactive selected reactive dyes

Steam time 3 - 5 min 6 - 8 min.

Market share ~60 - 65% ~5%

Usageresidential carpet, mats and rugs

Hospitality carpetPA 6.6 for commercial carpet

and rugsand walk off mats



Acrylic Polyester Cotton PolypropyleneOlefin

Good to excellent Good to fair Moderate Good. Avoid high piles.

Fair to excellent Good to excellent Moderate Excellent

Good to excellent -- Good if oily soilsGood oily stains should Moderate and stains are

be promptly treated. treated promptly.

Excellent resistance. Good - Loses strength andProlonged exposure may may weaken

Depending on dyesdeteriorates unless

cause deterioration in with prolonged chemically modified tosome pieces. exposure. resist sunlight damage.

Builds up in low Builds up in Builds up in low humidity humidity unless low humidity No static builds up but at a lower level than

modified. unless modified. nylon or polyester

Warm, softVaries - finer deniers

Warm and soft Waxy, softare soft and silky.

Excellent Excellent Medium Excellent

Acrylic burns readily Melts at 170°C; burns andunless modified. emits heavy, sooty, waxy

Modacrylics are difficult Burns slowly, smoke. Pulling a heavy to ignite, will not support melts; some are Burns slowly, object across the carpet

combustion, are self- self-extinguishing. self-extinguishing. surface can cause enoughextinguishing and dripless. Chemical odor. friction to melt the carpet

Acrid odor for both. fibers.

Cationic dyes Disperse dyesDirect, fiber reactive, sulfur, Can be printed with pigment

vat, and naphthol dyes dyes only

5 - 8 min 8 - 10 min 5 - 10 min --------

~5% ~5 - 10% ~3% ~20 - 25%

Bath mats, rugs Residential carpet Bath matsResidential

blanketscarpets andwoven rugs


1.2 Tufting

The first 12-foot-wide tuftedcarpet was manufactured inthe early 1950s. Pattern attachment devicespermit machines to producemultiple pile heights, geome-tric and other patterns in thesame piece of carpet.

The machines insert yarn intothe primary backing with up to2,000 needles and they canproduce patterns and texturesby combinations of pileheight, the position of yarn inthe needles and whether theyarn is loop or cut pile.

1.3 Carpet Backing

Primary Backing SystemsThe primary backing into whichthe tufts are inserted may bemade of jute, cotton, woven ornon-woven synthetics, but nor-mally polypropylene.

For printing the following constructions are popular:

1/10" loop pile for mats and scatter rugs with gel foam backing5/32" cut pile for mats, rugs and saxony constructions1/8" cut pile and level-cut-loop for residential and commercial

carpets1/10" cut pile for frieze and velour constructions for commercial

carpet

Popular tufting machine manufacturers:

Cobble, UK; Tuftco, USA; CMC - Card Monroe, USA

Woven Polypropylene Spunbonded Non-woven

Cost + ++

Dimension stability +/- +++

Good mendability, wet dye Ideal for carpets with distortion-

Propertiesprocessing, and stitch lock

sensitive designs such as prints and pattern tufting. Can be

accurately cut in any direction.

Application Most popular primary backing forCommercial carpet; car carpet,

residential carpetcarpet tiles, rubber backed mats,

bath-mats

Popular brands ‘Poly Bac’ by BP“Typar” (PA) by DuPont’

Lutradur’ (PET) by Freudenberg‘Colback’ (PET with PA skin) by

Colbond


Primary backing

Adhesive

Secondary backing


Secondary Backing Systems

This laminated final backing provides tuft-lock, stiffness, strength, stability, and thefeel of quality to theentire carpet.Dimensional stability,primarily imparted bythe secondary backing,is the ability of carpetto retain its size andshape after installa-tion.

Woven Polypropylene Polyurethan Cushion

(Action Bac ®)

Cost + +++

Comfort + +++

Composition,1. Direct application of latex or • primary backing

polymer to back of carpet face • urethane foamprocess,

(pre-coat) • optional fleece or woven PPconstruction

2. Light coat of latex or polymer to secondary backing

3. Layers are joined at compression rollers and cured in tenter frame oven.

Application residential and commercial carpet commercial carpet and carpet tiles

There is also a number of other backing systems:

• PVC and EVA - for carpet tiles and 6 feet wide carpet

• Bitumen with fleece - for carpet tiles

• Latex gel-foam with embossing - for bath mats and scatter rugs


1.4 Carpet constructions

Over all the years a number of tufting methods have been developed to produce carpets in different styles. In the following a selection of the most important constructions - especially for the printing process.

Level LoopMost common construction for cheap rugs and wall to wall carpet in Europe andAsia. This type consists of loops constructed at the same height. Patterns may beprinted on the surface of this style type. This type offers a relatively smooth,homogenous surface. Lower density construction mayallow the loops to be dispersed farther apart providingthe illusion of texture.

Cut and Loop Pile As the name implies, this carpet style utilizes a combination of cut and loop pileyarns to create patterns or textures. Multilevel Cut and Loop –These styles aregenerally random colored providing the appearance of color splotches over theentire surface. These styles offer good performance cha-racteristics and random colorations provide good soil-hiding abilities.

Velour (also called Plush or Velvet)Velour provide a more formal appearance than other cut pile constructions. Theyare subject to revealing vacuum cleaner sweep marks and footprints due to lightreflection, similar to a Saxony. Delustered (non-shiny) yarns may reduce thisshade variation. Plushes tend to be more subject to pile reversal or water mar-king. Water marking is the result of permanent pile reversal in localized areas.Watermarking provides the appearance of a wet surface indarker shaded areas. This is considered a normal occur-rence for Plushes and is not considered a manufacturingdefect.

Saxony A Saxony is a cut pile carpet in which two or more plies of yarn have been twistedand heat-set so that the tip of each carpet tuft is distinguishable on the pile sur-face. Saxonies have the tendency to show footprints and vacuum cleaner sweepmarks. This is due to light reflection of the fiber when piledirection is changed. This is not a defect of any kind, butmerely a characteristic of this carpet construction.

FriezeFrieze – A true Frieze is similar to a texture in that footprints and vacuum sweepermarks are disguised. The textured appearance is acquired by placed a high twistlevel on the plied yarn. This high twist level causes the tuft to twist back uponitself providing a kinked appearance. In general terms,higher twist levels provide enhanced performance charac-teristics, when compared to lower twist products with thesame construction attributes.



Carpet Fiber Identification by Burn Tests

• Nylon, Polyamide:

Melts and shrinks from anapproaching flame. In theflame, melts and burns slowlyand is smoky. Once out of theflame, burns slowly and tendsto self-extinguish. Burningnylon smells like celery. Itsburned residue is a hard, shinybrown or gray bead.

• Wool:

Chars and curls away from anapproaching flame. In theflame, it burns slowly andunevenly. Once pulled out ofthe flame it is self-extinguis-hing. It smells like burninghair. It has a brittle, irregularblack ash. As with cotton andlinen, protein fibers’ ashes rea-dily crumble.

• Acrylic:

Melts and shrinks from anapproaching flame and ignitesquickly. In the flame, burnsrapidly with bright, sputteringflame with a lot of smoke.When withdrawn from theflame, it continues to burn,melts, and drips. It has anacrid odor and results in ahard, irregular black bead.

• Polyester, Corterra:

Melts and shrinks from anapproaching flame. In theflame, melts and burns slowly.When withdrawn from theflame, it burns slowly, meltsand drips. Has a slightly sweetsmell. It produces a hard,shiny black or brown bead.

Use a butane lighter to melt or ignite an unknown fiber to determine its type. Never use a match.The purpose of using a butane lighter is to avoid masking the odor of the burning fiber since thebutane flame is odorless.

• Cotton/Linen:

Cellulosic fibers such as cot-ton and linen ignite readilywith an approaching flameand scorches. Once in theflame, it burns rapidly with ayellow flame. When pulled outof the flame, it continues toburn rapidly with a red after-glow upon extinguishing.Smells like burning paper. Itsburned residue is a gray tocharcoal colored light featheryash, which easily crumbles.

• Polypropylene (Olefin):

Melts and shrinks from anapproaching flame. In theflame, it melts and burns.When withdrawn from theflame, it continues to burn.It has a candle wax odor andproduces a tough, tan bead.


2.2 Thickeners (Gum)As regards quality in carpetprinting, a key role is played bythe flow behavior of the prin-ting paste. This is influencedby the thickener used. There isan extensive range of productsavailable for a wide variety offibers, carpet qualities, dyeclasses and printing methods.Thickener is a must in the prin-ting process. It keeps thedyestuff on top of the fiber toavoid 'frosting'. In addition itprevents the dye from migra-ting between the pile.

2.2.1. Thickener forscreen printing: Most thickeners for screenprinting are made of Guar,Xanthan, seaweeds…(= naturalthickener).These type of thickeners arerelatively inexpensive. The thickener is normally mixedto a so called 'stock thickener'- thickener with a very highviscosity which is then mixed ina certain portion (about 30-50%) with water, dye and otheradditives. The result is the

ready made print paste with acertain viscosity. The viscositydepends on the printing pro-cess and the quality of thecarpet.

Manufacturers for natural

thickeners:

CHT, Germany

Polygal, Switzerland

Raniechemie, Germany

2.1 Water in the Textile and Carpet Industry

Quality of process water isvery critical and important fora successful dye and print ope-ration. Especially water hard-ness is of importance. Hardwater will result in higherusage of chemicals, thickenersand in bad results of dyeingand printing. A water softener

is recommended and in anyway needed for the waterused by the steam generator.

In case of high concentrationof other minerals, elementsand impurities it is stronglyrecommended to use filters,chemicals and other methodsto reduce or remove them.


General Recommendation for Process Water in theTextile Industry

Appearance Clear, colorless, free of floating particles

Total hardness dH° 1 - 4 dH (<1.2 mmol/l = 22 mg/dl)

Iron mg/l <0.1

Manganese mg/l <0.1

Copper mg/l <0.1

Nitrite mg/l <0,01, should not be existent

pH value 6.5 - 8.0

Organic impurities KMNO4 consumption should be less than 20 mg/l

BicarbonateLimits are not available. If there is too much bicarbonate

in the water the pH would be varying towards the alkaline during the steaming process

Conversion mg/dl x 0.0555 = mmol/lmmol/l x 18.02 = mg/l


2.2.2. Thickener forChromoJet process:Chromojet works best with highperformance synthetic thicke-ning systems especially develo-ped for the jet print process.Most of these thickeners arebased on polyacrylate.

The following requirements

have to be matched:

• easy to dose, disperse and mix (Supra-Mix)

• good definition and sharp outlines

• high color yield• no frosting• highly stable viscosity

• good thixotrope properties• must not clog jets• easy to wash out and off• good ecological properties

(low COD and BOD)

Typical recipe for syntheticstock thickener:

980 - 970 g Soft water15 - 25 g Synthetically

thickener2 - 4 g Citric acid1 - 2 g Emulsifier /

(if needed)1 - 3 g Anti-foam

0,5 - 2 g Fungicide (if needed)

1,000 g Stock thickener

2.3 Chemicals for Dyeing and Printing

Besides thickener and dyestuff there are a number of otheradditives used during the printing process:

• Antifoams - to avoid foaming during the preparation and application of print paste

• Penetration and leveling agents• Resist chemicals - for resist printing • Preservation Chemicals- to avoid bacteria and fungus• Acid donors -to achieve a lower pH during steam process• Retarding chemicals - to avoid that the dye is fixed before

going into the steamer (cold strike).• Dispersing and leveling agents (affinity to fiber,

affinity to dyestuff ) • Wetting agents - to improve penetration of prints• Anti-frosting agents - to avoid frosting especially on velour

type carpet• Carriers - for disperse dyeing of Polyester carpets• Flame retardants or other finishing products• Foaming agents - for foam finishes

Popular suppliers for printing

and dyeing chemicals:

Bayer-Tanaprint

CHT, Germany

Zschimmer & Schwarz, Germany

Dr. Boehme, Germany

Allied Colloids, UK

Chematron, USA

Popular synthetic thickeners

(paste in drums or totes):

Tanaprint from Bayer-Tanatex;

Texipol from Scott Baader, UK;

Prisulon-CSD from CHT, Germany;

Alcoprint from Ciba, Switzerland;

Chemaprint from Chematron, USA


2.4 Dyestuff Selection


and family of dyestuff.Dyes should show similar diffu-sion and trichromatic behaviorand fixation rates. The combi-

Nylon, Polyamide (PA)

Acid dyes Pre-metallized dyes Reactive dyes

Light fastness +++ +++ +/-

Wash fastness +/- ++ +++

Brilliancy +++ +/- +++

Coverage of barriness +++ -- --

Ecological aspects +++/- -- +/-

Fixation time (Steam) ~3 - 5 min ~4 - 7 min ~5 - 10 min

Application For residential carpetContract carpet, Mats for laundry

automotive carpet industry, bath-mats

Remarks Good all over For dull shades For brillant shadesproperties

Popular dyes

Dystar Telon, Isolan, Isolan S, RealanTelon A, Telon M Isolan 2S

ClariantLanasan,

Lanasyn DrimalanNylosan

Ciba Tectilon, Erionyl Lanaset, Irgalan Eriofast

nation of fibers, dyes andauxiliaries must be selectedcarefully.

Fastness is always influencedby the type and constructionand the treatment (heat sett-ing) of the fiber, and the type


Acrylic (PAN) Polyester (PES) Cotton (CO)

Cationic dyes Disperse dyes Reactive dyes Direct dyes

(Basic dyes) (Substantive dyes)

Light fastness ++ +++ +/- +

Wash fastness +++ ++ +++ –

Brilliancy +++ +++ +++ ++

Coverage of barriness +++ +++ +++

Ecological aspects ++ + – +

Steaming time ~4-8 min ~8-15 min ~8-12 min ~5-8 min

ApplicationFor bath mats, rugs

Residential carpet For bath mats and rugsand mink blankets

Remarks

Quality of heat- Dyeing is done in Requires compli- Wash fast up tosetting is important pressure becks. cated after-treat- a temperaturefor rugs and mats. For printing a carrier ment. Process not <40° C/105° F.

must be used. recommended for For light andcarpet printing! medium shades.

Popular dyes

Dystar Astrazon Dianix Remazol Sirius

Clariant Sandocryl Foron Drimaren Indosol, Optisal

Ciba Maxilon Terasil Cibacron Solophenyl

Wool (WO)

Acid dyes Pre-metallized dyes Reactive dyes

Light fastness + +++ +/-

Brilliancy ++ -- ++

Ecological aspects +++ -- +/-

Steaming time ~6 - 8 min ~7 - 10 min ~8 - 12 min

ApplicationResidential carpets, Residential carpets,

Yarn dyingrugs rugs

RemarksLight and medium

For dull shadesshades

Popular dyes

DystarTelon, Isolan, Isolan S,

RealanTelon M Isolan 2S, Supralan

Clariant Lanasan, Sandolan Lanasyn, Lanasan Drimalan

Ciba Tectilon, Erionyl Lanaset, Irgalan Eriofast


3.1 Yarn Dyeing

All pre-dyed methods supply dyed yarns prior to tufting.

There are many types of dyeing methods available in the carpet industry today. This section doesnot list every one, but gives an overview. Dye methods are determined by styling, economics andquality.


Solution dyed yarnHank, Skein or

Space DyeingPackage Dyeing

Process This is a method of dye- In this method, carpet Space Dye machines useing fibers before they are yarns are wound onto up to 6 different colorsextruded. Pigmented a skein or put as a cone and achieve spots ran-pellets are mixed with into a kind of a dye beck. ging from 5mm to infinitypure nylon or polypropy- Usually solid color yarns for the Micro effects.lene while in the liquid are desired, but multi- • Passing through astate and then it is color may be obtained by pre-fixing chamber,extruded into fiber. Once plying yarns with • Yarn coiling onto extruded, the colors are different dye abilities. a continuous belt,permanent. • Dye fixing in a steaming

environment for up to 8 minutes

• Double-soak washing,• Drying, cooling and

winding onto final package

Advantage • Very large dye lots • Good side to side • Unlimited design• Color uniformity within match capacity

dye lots • Economical to use for • High production (up • Best light, wash and small dye lot quantities to 400 kgs per hour)

chloride fastness • Good color flexibility • Dyeing of any material

Disadvantage • Minimum color • Small dye lots • Limitations in solidflexibility shades

• High investment


3.2 Piece Dyeing of Tufted Carpet

This method refers to tufting a piece of carpet withundyed fibers and dyeing the “piece of carpet”.

Beck or Winch Dyeing Continuous Dyeing

Process Tufted carpet in lots between 50 and In this method, carpet moves “conti-400 meters is placed in a large beck nuously” through the dyeing machine. (bathtub) of water. Dyes are added and Undyed carpet enters the dye range at the water is heated. The carpet is kept one end, moves several hundred feet moving by the use of a reel, but always through dyeing, steaming, washing and stays within the beck. drying. Carpet in open form or rope form The carpet leaves the range as dyed

carpet. Continuous dyeing is associated with Kuesters, Germany.

Advantage • Good economics for small quantities • Good economics for large quantities• Very flexible in color selections • Large dye lots• Good color uniformity within dye lots • Combination of solid color with prin-

ting and gum applicators for Multicolorcarpet

Disadvantage • Small dye lots • High investment cost for a dye line or • High water and energy consumption a combined print- and dye line.• not for wool because of felting


3.3 Printing Methods for Tufted Carpet

Carpet printing can be carried out using Flat screens, Rotary screens or Chromojet process.Independent from the actual printing system there are a number of different printing methodswhich can be carried out by screen- or jet-printing systems.


Direct Printing Displacement

Resist PrintingPrinting

Characteristics The complete pattern Displacement printing is Resist printing is a two including the base color characterized by a dark step operation method.is printed. ground shade highlightedDisadvantage is that the by light and bright overprint color must printed colors.always be darker than This makes the carpet the base color. look more attractive.

Techniques In screen printing the Displacement printing In the first step the base color can also be can be done in two ways: spot colors are printed applied with a padder. a) Using a padder for the using acid dyes and In ChromoJet printing the ground shade and a special anionic resistbase color and the printer to overprint. chemicals to block aminoaccent colors are printed. b) Printing the spot groups. This will avoid

colors and over dyeing any color going onto with a dye applicator the fiber during theafter printing. This is subsequent dyeing the common method. process.

The condition for In the second stepperforming the displace- the carpet is over-dyedment technique is the using a dye applicator or use of dyestuffs with a winch. The previous different affinity to Poly- printed areas cannot beamide and cationic resist over-dyed and will remainagents. in the spot colors printed

in step one.

Direct printing is the Displacement printing is The advantage of this most common method common with screen process is that printing with ChromoJet printing. printing to overcome can be done in large runsAll colors are printed - the problem of low and the base colour canincluding the base color. penetration of printed be done at a later stage

colors. in short runs by winch orcontinuous using an overflow applicator (Quick Change).

Advantage Simple method High water usage Best definition of colorseparation of prints

Disadvantage In screen printing only Long process, high costdark colors on light shade


Each print line is different and built according to the marketand to customers demand. In the following a general overviewof some basic elements of a print line.

CARPET SEW-ON

(BUTT-END

SEAM)

FEEDING FROM

ROLL OR TROL-

LEY

ACCUMULATOR

OR J-BOXLINT REMOVAL

CENTERING

UNITPRE-STEAMER

PADDER PRE-WASHING

ROTASCREEN CHROMOJET

GUM LAYER

DYE

APPLICATORSTEAMING WASHING DRYING

BACKING

FLOUR-

CARBON

ANTI-STAIN STEAMING WASHING



Layout of a Carpet

Print Line


4.1 Carpet Entries

The entry unit is very important for an efficient dye or print line. Carpet is un-rolled, conditionedand prepared for the print process.

Sew-on To sew rolls together. Butt seam machines are preferred

Un-rolling Lateral controlled un-rolling cradle

J-boxTo store carpet to allow sufficient sewing time. Used for carpet without backing.

Accumulator For backed carpet an accumulator is recommended instead of J-box.

Beating, pile raising

and vacuum unitTo remove loose fibers and lint; to open and equalize the pile.

Pre-washer (optional)To remove unwanted lubricants and grease.Necessary for dye lines. For ChromoJet printing process not common.

Pre-SteamerTo remove crush marks and to improve affinity of the fiber. Bulking and realignment of pile; equalizing of fabric tension

Dye Padder (optional)To apply the ground shade to the carpet – especially for loop pile qualities. Constant pressure between rollers over the width is most important for uniformity (Kuesters S-Roll technology).

Guiding systemsPivot frame guider for edge or center control by means of contact free sensors

Pull roller Pull roller and synchronization

Compact entry unit for 2 mlines with integrated carpetlift; guiding; pre-steamer;and pull roller.

Feeding from trolley; J-box; lintremoval; pre-steamer; padder; pivot guider; pull roller

Un-rolling; accumulator; lint removal;pre-steamer; pivot guider; pull roller



4.2 Printing Machines The selection of the printer is the most critical decision.Depending on the market, required production speed, type ofdesign - the decision could be made between screen printer ordigital jet printer

ChromoJet ChromoJet-F RotaScreen

System and

Jets are mounted on a Jets are mounted on a Rotary screen printer.

characteristics

traversing print head. fixed print head across Carpet moves continu-Carpet moves inter- the carpet. ouslymittently Carpet moves continu-

ously

DesignsIn digital form; prepared In digital form; prepared Engraved screens with any graphic program with any graphic program One screen per color

Repeat size

No limitation; repeats up No limitation; repeats up Limited by circum- to 100 m are possible to 100 m are possible ference of screen.

Typical 923; 1017; 1206, 1410,1621 mm

Color penetrationFull penetration can be Full penetration can be Limited to about 2-3 mm achieved achieved

Print speed0,5 to 10 m per minute - Up to 30 m per minute Up to 35 m per minutedepending on number of jets per color

Number of colors8, 12, 16, per print head One color per head - up Up to 16 colors16, 24 or 32 in Twin-Head to 12 colors max. configuration

Investment

From low to high - High - Medium -depending on print Depending on number Depending on number capacity and number of of colors and width of colors and widthcolors

Application

For individual production For high speed For low-end wall- to-wallof rugs and wall to wall production of jet printed carpet and small scattercarpet especially for the carpet. Especially in com- rugs in high volume.contract market. Most bination with continuous universal carpet printing dye lines to produce system. multi-color designs.

ChromoJet ChromoJet - F RotaScreen

4.3 Gum and Dye Applicator


On slow running lines the gumcan also be applied using aprint screen.

Dye Padder Fluidyer Gum applicator Over Flow

Function

PrincipleCarpet passes a Pressurized dye is Gum is applied to Dye is applieddye bath and 2 injected via a slot the carpet without contact topressing rollers the carpet

Pick-up 80 - 100% 100 - 500% 100% 300 - 500%

Application

To apply base For continuous dye For special frosting Contact-free shade and wetting lines and to apply effects on level- application of agents before the base shade before cut-loop construc- base shades on printer - especially the printer - tions. In combina- high pile carpet. for loop pile carpet. especially for high tion with Over-Flow Also in combina-Also in combination pile carpet in applicator. tion with gum with Chromojet combination with applicator and

ChromoJet-F and print. RotaScreen

PositionBefore printer Before printer Behind printer Behind printer

and before Over- and gum Flow applicator

Remarks

Swimming rollers Also with Kuesters Minimum speed of Also with quickby Kuesters are quick change about 5 m/min change option.recommended to option - to mini- Minimum speed avoid side-center- mize loss of carpet of about 5 m/minside differences. between color

changes.

Solid dyeing of carpets is donein continuous dye lines. Mostof these lines are using aFluidyer or an over flow appli-cator.

For solid shade dyeing a pickup of about 300- 500% isrequired (Fluidyer or over-flow).When base color is applied incombination with over-print(wet on wet) then a pick-up ofabout 100% is required (dyepadder or Fluidyer)

For special frosting effects(light tips on the fiber) a com-bination of a gum and an over-flow applicator is used.

4.4 Steamers



• even temperature profile over the width and the length of the steamer

• no condensation drips at entry and from roof

• low energy waste - good insulation

• short heat up time• enough support rollers for

Basic type of steamers

Horizontal steamer Vertical steamerHorizontal -vertical

steamer combination

PrincipleCarpet runs horizontally Carpet runs in vertical Horizontal and vertical throughout the steamer loops steamer in combination

Characteristics+ Mechanically simple. - Mechanically more Printed carpet should- Occupies a lot of space complicated. remain 1 - 2 minutes in

in the length. horizontal section

Investment Moderate High High

Application

For ChromoJet printing. To improve levelness in For screen printing linesPrinted color will stay in dye lines. Color can and fast running place migrate. Chromojet lines. Good

Not recommended for compromise between allprint lines. over length and contents.

Carpet content of steamer must match required steam time(total carpet contents = print speed x steam-time)

The following criteria must be matched:

the carpet on horizontal steamers

• inspection windows at leastin first section

• exhaust at entry and exit to prevent steam from escaping

• easy to transport, install and uninstall

Combined horizontaland vertical steamerwith additional loopat entry for soliddyeing. This loop isnot in use duringprinting.

The steamer is a very critical part of the print and dye line. Due to the open construction and theusage of saturated steam the temperature will be at the boiling point. The actual steam temperatu-re depends on sea-level and weather and is always somewhere around 100° C (212° F).

Type of steam supply

External generation of saturated steam


Steam generation

Sump steamer Cloud steamerSump and Cloud

Combination

Function

Steam is injected into a Steam is injected into an Main supply comes from sump of water inside of external water-sump cloud but at entry of the the bottom of the steamer. (steam saturator) and the steamer an additional Saturated steam is saturated steam is sump section is used togenerated on the back supplied from top of the generate enough side of the carpet. steamer (pile side) capacity of steam.

Characteristics

+ High steam capacity + Short heat up time + Good combination of - Long heat up time. + Very efficient efficiency and uniformity

- Could give problems at - Higher investmentthe beginning of a runwhen load is changing and high steam supply is needed.

Remarks Good for dye lines and for Recommended for print For combined print andsmall print lines lines - especially for dye lines

carpet with backing

Injection cooler with fixed jet orificesThe cooling water is injected through specialjet orifices. The amount is adjusted by a controlvalve mounted upstream of the desuperheater.

Water-bath desuperheaterSuperheated steam is injected into the watercontained in the desuperheater. The heat of thesuperheated steam is given up to the water.The steam produced is conducted throughsteam separating units and reaches a steam-content of more than 98 %.

Steam outlet

Electric temperaturecontrol

Cooler withequipment

Pressure reducingstation

Drain

Coolingwaterinlet

Steaminlet

Steam outlet

Steam inlet

Pump unitDrain

Pressurereducingstation

Coolingwater

Desuper-heater

Waterlevel

control

4.5 Washing Systems

• Washing in a print line should be done immediately after the steamer. • Water is sprayed onto the carpet pile where the residues are diluted. The following high power

suction slot removes the water down to a remaining moisture level of about 40 - 60%.

This type of washer is used especial-ly for individual carpet tiles andmats. Pieces are running between asandwich of two conveyors (a trans-port conveyor and a open meshconveyor), where the water is suckedthrough the mesh.



a) Sandwich washer for carpet tiles and individual mats

This type of washer is most common for wide print lines.It is a spray - suction - spray - suction process.Water is sprayed onto the un-backed carpet from the backside just ahead of the vacuum slot. There are several other configurations available (thickenerrecycling; third slot).

b) Twin-Slot washer for wider lines with higher line

Vacuum pumps

Depending on width and typeof carpet different types ofvacuum pumps can be used.

One stationary suction slot in4 m width uses about 45 - 55kVA of electrical energy for thevacuum pump.


This picture shows a 110 kWwater-ring vacuum pump withseparator.

Pump Selection

Water-Ring-Pump Roots Blower Centrifugal Blower

Efficiency Medium Very efficient Very efficient

Vacuum level Up to 60 kPa Up to 50 kPa Up to 40 kPa

Air volumeLow - especially for Medium - universal High - for un-backed carpet with backing carpet

Adjustment of No - fixed speed only Yes - in a wide range Yes - in a wide rangevacuum by rpm

Noise levelMedium Loud - needs Low

encapsulation

Cooling waterYes - but will be used for

washing the carpet No No

Investment Low investment Moderate High

Remarks Very robust; Needs good filtration Needs good filtrationMany solids, water and and separation and separation

textile fiber, can be passed through the

liquid ring pump withoutdamage.

4.6 Dryer

a) Flow-Through Dryer with Tenter Frame

There are different concepts for dryers depending on production speed, quality, heating mediumand carpet quality.



Carpet Dryers

Flow-Through Dryer Double Impingement Dryer

Principle Air passes the carpet from Air is blown from top andabove. Most efficient dryer for bottom onto the carpet. carpet without backing. Driven Used for very dense carpet and support rollers avoiding high carpet with backing. Amount tension in carpet. of air from bottom can be set

by means of flaps.A conveyor belt carries the carpet throughout the dryer to avoid any bowing and skewing.

Drying capacity on backed –––– Up to 8 kg /h and per m2

carpet

Drying capacity on un-backed Up to 30 kg/h and per m2 Up to 15 kg/h and per m2

carpet

Conveyor belt OptionalStandard (when used for backed carpet)

Tenter frame StandardOptional (when used for un-backed carpet)

Length of one segment 3 m 4 m

Circulating fans2 x 22 kW per segment with 2 x 11 kW with speed control

optional speed control

Width 4.3 and 5.3 m 2 - 5.3 m

Shortest and most effective dryer concept in combination with a tenter frame and a cooling zone. Air is blown through the carpet and therefore this method works only on carpet without backingwhich allows that the air passes through. To avoid high tension either support rollers or a conveyorbelt is used.

b) Double-Impingement Dryer

Double impingement dryer with 2 gas-heatedsegments. Carpet is carried by an open meshpolyester conveyor belt.


Heating Medium for Dryers

Gas heating Most efficient heating medium. Especially recommended for big dryers. + Short heat-up time - Strict safety regulations- Requires minimum amount of exhaust air- Not recommended for acrylic

Steam heating Recommended for smaller lines.+ Easy to control+ No minimum exhaust air needed- Takes more time to heat up- Limitation in max. temperature (about 140° C/280° F)

Thermo-oil heating Only recommended where Thermo-oil is already in use and available.

4.7 Accumulator and Roll-upAn initial accumulator (compensator) separatesthe print line from the inspection area so thatcarpet can be inspected and rolled up inde-pendently from the print process.

In case the carpet is printed with backing thena centering unit (pivot guider) is recommended. In case the carpet is printed without backingthen a winder with lateral control is recommen-ded.

Radically different from allother methods of printing,ChromoJet needs no screensand is revolutionary in its abili-ty to create unlimited patternrepeats.

ChromoJet works with pre-mixed spot colors which are filteredand pressurized. Pressure (between 1 and 3 bar) depends onviscosity and pile height.

Deepest color penetrationand excellent print definitionare results from electronics,mechanics and chemistry. Chromojet prints compare tobest tufted and woven car-pets.

Jets are arranged in groups,mounted on a print-headwhich traverses the carpet.


The computer controlled jets open and close up to 400times per second. The color pressure injects dye with surgi-cal precision deep into the face of the pile without anymachine parts touching the fabric.


Design systems

• Designs can be made on any Windows based design system like Adobe Photoshop, Corel Photopaint; Jasc Paintshop and many more.

• Special design systems developed for the carpet and textile market can also be used like Nedgraphics, APSO and several others..

• The PCX file format is used as direct input for the Chromojet but third party conversion programs are avai lable for all common file formats.

Print speed on ChromoJetmachines with moving head

Resolution

10 dpi - For high pile carpet and for ChromoJet-F in combination with continuous dye ranges

16 dpi - The industry standard. A good compro-mise between speed and definition

20 dpi - Especially for carpet tiles 24 dpi - For fine velour type products - but not

common yet32 dpi - Future development

Modes of Operation:

Single Speed Mode (SSM)

Each group of jets is used for an individual color.

Double Speed Mode (DSM)

Two groups of jets are combined and filled withsame color. The linear production is almost dou-bled in comparison to the single speed mode.

Production speed is almost propor-tional to the number of jets usedper color on the moving print-head.As more jets are used per color thehigher is the production speed.


Twin-Head ConceptOn one printer there are 2 identical print heads eachwith a certain number of colors. A Twin-HeadChromojet offers a higher number of colors and moreflexibility.

Example: If we have 2 heads each with 12 colorgroups:


4 modes of operation• Head A is printing while head B is prepared for

the next run• Head B is printing while head A is prepared for

the next run• Head A and head B print in single speed mode.

This gives up to 24 colors• Head A and head B prints in double speed mode.

This gives up to 12 colors but double speed.


5.1 ChromoJet Selector

Printing width from 2 to 5 mand 8 to 640 jets per color -each Chromojet is custom builtto fulfill the demand of thecustomer and to deliver theright product for the market.

The total production speed isalways depending on the num-ber of jets per color. Doublenumber of jet means double-production speed (in m2).

ChromoJet Selector

Products to be printed

~ Production

Piece by Piece operation Roll to Roll operationper year in a 2 shift operation (16 hours)

Mats Carpet Tiles 2 m Lines

4 m Lines for 5 m Lines forWall-to-Wall Wall-to-Wall

+ Rugs + Rugs

10 - 25,000 m2 CHR MP

25 - 50,000 m2 CHR MP-plus

50 - 100,000 m2 LT-2000/c* x 16 LT-2000/c x 32

100 - 250,000 m2 LT-2000/c x 32 LT-2000/c x 64 LT-2000/c x 32

250 - 500,000 m2 M-2000/c x 128 LT-2000/c x 64 MT-4000/c x 64

0.5 - 1 mio m2 M-2000/c x 128 M-4000/c x 128

1 - 2.5 mio m2 ChromoJet-F M-2000/c x 256 M-4000/c x 256 M-5000/c x320

2.5 - 5 mio m2 M-4000/c x 512 M-5000/c x 640

5 - 10 mio m2 ChromoJet-F

The number of colors is depen-ding of the application. Mostlines have 8, 12 or 16 colors. It ispossible to have machines withup to 32 colors.

*'c' is variable and stands for number ofcolors per print head.

Besides our standard program we also buildhighly customised printers in various confi-gurations.


6. ChromoJet - Printing Systems

6.1 Logo-Mat Printing

With ChromoJet technology itis simple to create customdesigns with up to 32 colors.Custom made mats are the per-fect solution for everyone whowants to put out the name forall to see. Today most of themajor mat suppliers are offe-ring ChromoJet printed mats.

• Typical number of mats per order is in the range of 1 to 10!• Mat printing machines have 16 or 32 colors so the number of

color changes is minimized. • Flexibility is more important rather than speed. • Full penetration of dye and best wash fastness is achieved by

using selected fibers and dyestuff.• The Chromojet Mat Printer can handle any size of mats up to

the full print width.• Mats can be printed with or without backing (PVC, rubber,...)• Piece-by-piece or roll-to-roll operation.• One conveyor from steamer to exit.• Applicator for stain and soil release chemicals and post

steamer optional.

MP MP-plus MP-2000/ c x 16 MP-2000/ c x 32

Print width 155 cm 215 cm 215 cm 215 cm

Number of colors 16 32 16 or 32 16 or 32

Jets per colour 4 8 16 32

Print speed~ 0.1 m/min ~ 0.2 m/min - ~ 0.4 m/min - ~ 0.7 m/min -

~ 10 m2/hour ~ 20 m2/hour ~ 40 m2/hour ~ 80 m2/hour

Max. annual capacity in 2 shifts

~ 10 - 15,000 m2 ~ 20 - 30,000 m2 ~ 40 - 60,000 m2 ~ 80 - 120,000 m2

Steamer

Conveyor belt Conveyor belt Conveyor belt Conveyor beltsteamer, steamer, steamer, steamer,

about 0.7 m about 1.2 m about 2.2 m about 4.4 m in length in length in length in length

WasherShuttle type Shuttle type Shuttle type Shuttle type

washer washer washer washer

Applicator Yes Yes Optional Optional

Post steamer No Optional Optional Optional

Post washer No Optional Optional Optional

Dryer Special dryer Special dryer Conveyor belt dryer, Conveyor belt dryer,

3 m active length 6 m active length

Heating medium Electricity Steam or electricity Steam Steam

Required space ~ 4 x 8 m ~ 6 x 12 m ~ 8 x 30 m ~ 8 x 40 m

Application

Mat printer for Most versatile mat For professional mat For professional matlaundries, printer, manufacturers manufacturers

sign and banner 32 colours! with high demandshops ...


“Shuttle washer” to removethickener and unfixed dyes

ChromoJet-MPThe most compact 16 colorChromojet print line for highquality mats with rubber backing.

16 colors are grouped with4 jets per color

Electrical heated steamer to fixthe dye onto the fiber

Efficient hot air dryer withelectrical heating

Start your own business -

print Logo-Mats!



ChromoJet-MP plusThe most universal mat print linein a compact form.32 colors and a print width of210 cm guarantee highest flexibi-lity, efficiency and productivity -no matter if a single mat or aseries of hundreds must be prin-ted.


ChromoJet-LTPrint line with 16 or 32 colorsand 16 jets per color. To print on roll to roll or on indi-vidual mats.

ChromoJet-LT plusThe ultimate mat print line with32 colors and 32 jets per color.printing - steaming - washing-staingard application - poststeaming - post washing - drying.To print on roll-to-roll or on indivi-dual mats.


6.2 Carpet Tile Printing

Chromojet is perfect to printcarpet tiles either as individualtiles or in form of slabs wheretiles will be cut out after theprinting process.

Printing can be done either onpre-dyed tiles with a light basecolor or on white tiles.

It is also possible to print onerepeat over several tiles toform a large scalepattern.

Tiles are manually loaded onto the open meshconveyor belt of the printer and put in registra-tion by means of the unique 'positioning devi-ce'. This allows to print the pattern with perfectregistration.The positioning device can handle tiles in anysize up to 100 x 200 cm.

To keep the perfect registration it is importantthat the backing (PVC, bitumen, hot-melts,foam; non-woven; …) is not overheated duringthe steaming and drying process. A 'heat-shield' in the steamer avoids high temperaturefrom the bottom.

An extra long dryer guarantees a gentle dryingprocess at low temperature.

Washing is done by the especially developed'sandwich washing machine'. The tiles areseparated by an open mesh belt from the vacu-um slots.


Positioning device for individual tiles

Individual tiles on open mesh conveyor belt


• Tile positioning unit for tiles up to 1 m

• Open mesh conveyor belt toallow over-the-edge prints

• Conveyor belt throughout the complete line

• Heat shield in steamer to avoid overheating of the backing

• Steam supply from top• Special sandwich washer • Low temperature dryer with

long drying time (10 - 20 minutes)

ChromoJet printed carpet tile installation made by Interface, UK

Chromojet Configurations for Carpet Tile Printing

LT-2000/c x 32 LT-200/c x 64 M-2000/ c x 128

Print width 215 cm 215 cm 215 cm

Number of colors (c) 8, 12, or 16 8, 12 or 16 8, 12 or 16

Jets per color 32 64 128

Print speed ~ 50 m2 per hour ~ 80 m2 per hour ~140 m2 per hour

Max. annual capacity

in 2 shifts100 - 150,000 m2 150 - 250,000 m2 250 - 350,000 m2

Steamer 4.4 m conveyor belt 6.6 m conveyor belt 8.8 m conveyor beltsteamer with heat steamer with heat steamer with heat

shield shield shield

Washer Sandwich type washer Sandwich type washer Sandwich type washer

Applicator Optional Optional Optional

Post steamer Optional Optional Optional

Post washer Optional Optional Optional

Dryer 8 m conveyor belt 12 m conveyor belt 16 m conveyor belt dryer dryer dryer

Required space ~10 x 30 m ~10 x 40 m ~10 x 45 m

Application Entry and roll-up unit can be attached to print also roll-to-roll carpetin 2 m width


6.3 Small Production Lines for Roll-to-Roll Operation

For "starters" and smaller ope-rations Zimmer offers a rangeof small production print lines:

These lines are made toprint rugs, mats and bathroom sets on 2 m widetufted carpet with orwithout secondary bak-

king (gel-foam or woven PP).

This means that manufactu-rers without its own backingoperation can start printing byusing white, semi- finishedcarpet to print on.

Small production lines arevery compact and straight for-ward.

Most of these lines are used



ChromoJet Small Production Lines

LT-2000/ c x 32 LT-2000/ c x 64 M-2000/ c x 128 M-2000/ c x 256

Print width 215 cm 215 cm 215 cm 215 cm

Number of colors 8, 12 or 16 8, 12 or 16 8, 12 or 16 8, 12 or 16

Jets per color 32 64 128 256

Print speed ~0,8 - 1.5 m/min ~1,5 - 2.8 m/min ~2.8 - 5.2 m/min ~5.2 - 8.8 m/min

Max. annual

capacity in 200 - 300,000 m2 400 - 600,000 m2 0.6 - 1 mio m2 1.2 - 1.8 mio m2

2 shifts

Steamer 6.6 m long 11 m long 20 m long 32 m long

Washer Twin-Slot washer Twin slot washer Twin slot washer Twin slot washer

Applicator Optional Optional Optional Optional

Post steamer Optional Optional Optional Optional

Post washer Optional Optional Optional Optional

DryerConveyor belt Conveyor belt Conveyor belt Conveyor beltdryer 4 m long dryer 8 m long dryer 12 m long dryer 20 m long

Roll-up Surface winder Surface winder Surface winder Surface winder

Required space ~10 x 30 m ~10 x 50 m ~10 x 70m ~10 x 90m

Application Rugs, mats, bath-mats, 2 m wall-to-wall carpet; acrylic blankets; artificial fur

for specialty carpet where flexi-bility is more important thanspeed.


Entry section with take-up plaited carpet from trol-ley; J-Box; lint removal; pre steamer; pivot guiderand pull roller.

Horizontal steamer with special steam generationfrom top or bottom.Conveyor belt or support rollers to transport thecarpet.

Double impingement dryer with variable fan controlallows short drying time. Roll-up or plaiter at exit.

Sandwich Washer for individual mats or tiles.Shuttle Applicator to apply stain-blocker products.

Twin-Head Chromojet printer with 2 x 8 colors and32 jets per color.Conveyor belt with pins is used to allow a perfecttransport and indexing of the carpet during theprinting process.



Chromojet LT 2000 /16colors x

32 jets

Compact entry unit; ChromoJet;2 section steamer; washer;double impingement dryer;(roll up not shown).

2 m print line with entry, 16 color printer, steamer, shuttle washer, post steamer and dryer

2 m Chromojet printline for mats and rugswith 16 colors and 16jets per color. Dyes supplied frombarrels and movabletanks.

6.4 Production Printer for Rugs and Wall to Wall Carpet

Rug printing with Chromojet is very popular. Highflexibility in colors and no restriction in repeatsand design sizes is the major advantage overscreen printing, weaving or tufting. White tuftedcarpet reduces stock dramatically compared towoven carpets.

A wide range of print lines in 4 or 5 m width with8, 12 or 16 colors and also the possibility to havethe Twin-Head option make Chromojet to the mostpopular printing system worldwide. Lines can be laid out to print on carpet with bak-king with optimum dimension stability (for thecontract market and for rugs) or to print on carpetwithout backing (for residential carpet and forlower end rugs). In all cases we use our know how and experienceto create a line with high performance - for todayand tomorrow.



Chromojet Production print lines in 4 or 5 m in width

MT-4000/ c x 64 M-4000/ c x 128 M-4000/ c x 256 M-5000/ c x 640

Print width 415 cm 415 cm 415 cm 415 cm, 515 cm

Number of colors 8, 12 or 16 8, 12 or 16 8, 12 or 16 8, 10 or 12

Jets per color 64 128 256 640

Print speed

(on 4 m width)0.8 / 1.7 m/min 1.7 / 2.9 m/min 2.9 / 5.5 m/min Up to 10 m/min

Annual capacity in

a 2 shift operation0.5 - 700,000 m2 0.9 -1.2 mio m2 0.9 - 1.6 mio m2 3.5 - 5.5 mio m2

Steamer Horizontal steamer with conveyor belt or rollers

Washer Shuttle washer Twin slot washer Twin slot washer Twin slot washer

Applicator Optional Optional Optional Optional

Post steamer Optional Optional Optional Optional

Post washer Optional Optional Optional Optional

DryerConveyor belt Conveyor belt Conveyor belt tenter frame

dryer or tenter frame or tenter frame dryer dryer dryer

Required space ~ 15 x 50 m ~ 15 x 60 m ~ 15 x 70 m ~15 x 100 m

Application Rugs, residential and contract carpet


Pump station with filters 12 color print head with 128 jetsper color at Jackson Carpet,China

Printhead at Durkan Carpet,USA with 12 x 384 jets

Computer room, steamer,washer and dryer

10 color head with 640 jets percolor at MAC, Egypt

Printhead with 16 colors and 64jets per color at Classic Carpet,Indonesia

Showroom with ChromoJet printed Rugs




4 m line with 16 x 64 jets ;steamer, washer and dryerwith conveyor belt

Chromojet Twin-Head print line with2 x 12 colors and 128 jets per color; entry, printer, steamer, washer,dryer, accumulator, roll-up

The Ultimate Combination of Flexibility and Speed

Instead of the traversing headthe jets are arranged on statio-nary bars (F- stands for the'fixed' print-head) across thecontinuously moving carpet. Each head represents one colorand is operated individually.

• Linear print speed of up to 30 m/min (100 feet/min) • No limitation on repeats• Full penetration • The washing, service and color change is done offside

while other heads are in operation. • Ideal in combination with dyelines for multi-color effects

7. ChromoJet-F - Speed and Flexibility

Some heads are printing and 3 heads are in service position

Operating panel with pressure controlfor each head

Jet plate from underneath with 2,432 jetsper color and 1/16" gauge resolution


Rug printing with ChromoJet-F 8 color ChromoJet-F at Bahlas, Saudi Arabia

Padder - for pre-wetting of high pile carpet

Gum Applicator - for shading effects

Dye Applicator - for the base color

Chromojet-F - for accent colors and designs

Padder Gum- and Dye Applicator ChromoJet-F Printer SteamerPivot Guider

ChromoJet-F in combination with continuous dye lines adds a

new level of creativity

Multi-Color Printing


Characteristics

Typical applications of

Screen printers

• loop pile carpet with base color applied by padder

• needle felt carpet with pigment print system (printing and drying only) flockedcarpet

• velour carpets in resist printing technology

• Level-cut loop carpet with multi-color effects

Saxony constructions in displa-cement technique

Zimmer Magnet System

A magnet beam is mountedacross the width under eachscreen. Electric magnets pulldown the light weighted roller-squeegees according to theadjusted magnet force.

• absolute even pressure across the width

• low weight roller squeegees for easy handling

• wide range of penetration and definition control

8. RotaScreen - Carpet Screen Printing

repeat, color and magnetcontrol on each print head

individual screen heightadjustment from 2 - 20 mm

• print width from 2 - 5 m • print speed up to 35 m/min• Magnet System for stepless

adjustment of squeegee pressure to achieve highest definition

• motorized control of length, -cross and diagonal registration

• light weighted color pipes and squeegees as well as an open bearing system guaran-tees easy handling

• dual screen drive with modern PLC control and touch panel operation

• repeats up to 200 cm • pull roller to adjust tension

of carpet• can also be combined with

Chromojet-M or Chromojet-F

RotaScreen was developed by

Zimmer beginning of the 70’s

for the fast growing carpet mar-

ket where high print speed up

to 35 m(100 ft)/min is needed.

The lacquer screens are engra-

ved with the design and the

color is pressed through the

screen.

Screen printing is the system

for low and medium quality

carpets in high volume.


Screen set-up with simple hoist Screen washing device for 2 screens;also used to insert the squeegee intothe screen.

Color pipe and squeegee washing

Entry with pre-washing Gum and dyeapplicator

Rotascreen Steamer


9. Sample and Lab Equipment


Zimmer also provides and builds basic lab equipment and other innovative machines:Viscotester, Mixers, Steamers, Drying Chambers, ChromoJet and RotaScreen Sample Printer,Filters, Special Applicators …..

ViscoTester VT02 is the most simplerotational viscometers. It has beendesigned for viscosity measurementsas a simple and sturdy QC tool. Themodel VT 02 is the standard visco-meter in the carpet industry.

Lab mixer with air motor (adjustablespeed). Very simple and robust. For batches up to 5 liters.

Sample Steamer - Mini

sample size: 65 x 65 cm sump heating: electrical, 12 kW


Mixer with stand

Robust air motor withvariable speed. Specially developedhomogenizer blades forhigh shearing effects. For batches up to 100liters.

Rotor-stator homogeni-zer with variable speed.Batch sizes up to 500liters. For dye preparation withstock or concentratedthickener.

Sample Steamer - Midi

sample size: 140 x 140 cmsump heating: 21 kW electrical heating or

optional with steam heatingThis steamer is used in combination withChromoJet or RotaScreen sample printer.

9. Sample- and Lab Equipment


Chromojet-LS650 - Mini

Sample printer for lab- anddevelopment work. print size: 55 x 65 cmnumber of colors: 16jets per color: 4

Shuttle-Spray Applicator

for lines with speed up to 5 m/min. Appliedamount is independent from line speed andcan be varied in a wide range.To apply stain - and soil release products.


Chromojet-MP

is also used as a 16 colorsample printer with integra-ted steamer, washer anddryer.

Sample width : 155 cm (60")colors: 16jets per color: 4electrical load: 25 kWsize up to 155 cm in widthand any length. Perfect for a 'all in one'sample department.

Barrel pump with micro con-troller with pre-set functionfor precise dosing of chemi-cals and thickeners. Controller can be calibratedfor any worm type pump. Accuracy of +/- 3%

Filter station

with 3 in-line filters withautomatic cleaning andrinsing function.For filtration of chemicalsand recycled thickener.


Characteristics• automatic dosing - no manual weighing and

measuring• accuracy of +/- 2% of the quantity• modular system with different sizes of pumps• product monitoring • wide range of viscosity of the individual

components and the end product• full yield of thickener and better mixing

and dispersion - up to 20% higher viscosity• lump-free and air-free paste; no contamination

with bacteria• immediate change of recipes and quantities• up to 20 dosing pumps can be installed• mixing capacity of 500 - 9,000 kg per hour

SupraMix is an in-line dosing,mixing, dispersing, homogeni-zing and pumping unit to pre-pare stock gum and other mix-tures from liquids and pastes.

Patented continuous dosingand mixing techniques arecombined in one unit. Theadvantage is a compact andhighly efficient system with

outstanding mixing capacity. The dosing of the individualcomponents is made by eccen-tric worm pumps.


SupraMix Technology and Function

One or more liquid phases, aswell as unsuspended particles,are passed by a forced-feedpassage through the rotor-sta-

Pumps

tor-system. The in-line-princi-ple effects a defined and repro-ducible application of shearforces. By varying parameters,

the desired dispersing orhomogenizing effect can beinfinitely adjusted.


Mixing and Dispersing Turbine


SM 500 SM 1000 SM 2000

Capacity (kg per hour) 900 kg/h 6,000 kg/h 9,000 kg/h

Dosing pumps number of dosing pumps and range of delivery will be setaccording to application

Monitoring of base

componentseither at inlet or directly at the chemical holding tanks

Accuracy +/- 4% +/-4% +/- 2%

Recipe storage no no yes, up to 30 recipes

Batch operation only manual start-stop or by level sensors yes, pre-setting from 10 to 990 kg

Integrated discharge pump no no yes

Turbine speed adjustable between 1000 - 6000 rpm

Water pressure at inlet 4 - 6 bar 4 - 6 bar 1 - 4 bar

Electrical load 5 kw 10 kw 12 kw

Most economical Specially for stock For special model. Recommended thickener preparation applicationswhere recipes have for Chromojet not to be changed production linesvery often

Supra-Mix 500

with 4 chemicalsSupraMix 500 - dosing pumps with injectionvalves, mixing turbine and outlet.

SupraMix 2000 - Control system with PLCand frequency converters.


Application

• thickeners and pastes for pigment printing

• stock thickener for carpet printing

• chemicals for pre- and post treatment

Pigment Recipe

Binder A 20 - 200 g/kg

Binder B 20 - 200 g/kg

Fixing Agent 4 - 40 g/kg

Synth. Thickener 4 - 40 g/kg

Ammonium 2 - 20 g/kg

Urea 2 - g/kg

Anti-Foam 0.5 - 5 g/kg

Water x g/kg

Total 1,000 g

Stock Gum for Chromojet

Citric Acid 0.5 - 5 g/kg

Emulsifier or Wetting Agent

0.5 -5 g/kg

Anti-Foam 0.5 - 5 g/kg

Synth. Thickener 4 - 40 g/kg

Water x g/kg

Total 1,000 g

Stock gum

H2O

SupraMixH2O

Thickener + Chemicals

• emulsions • lubricants• oils and fats• lotions• cleaners• detergents

Typical setup of a Supramixfor thickener preparation,with thickener holding tankand color mixing tanks.


Continuous Dyeing Carpet PrintingKuesters offers INSTACOLOR -a fully automatic 'Color-on-demand' system. Dye stocksolutions are mixed continu-ously to the dye liquor which isapplied to the carpet ondemand and in-line.

A fully automatic color prepa-ration system is expensivebecause multiple print headsor color groups must be ser-ved. Another problem is theusage of thickener which ismuch more difficult to handleand to wash. Therefore manu-al operated color preparationsystems with mixing tanks indifferent sizes are most com-

mon in the carpet printingindustry.

Zimmer recommends a semi-automatic color kitchen withcombined dissolving andmixing tanks. The actualdyestuff dosing and weighingprocess is separated from thedye preparation and mixingprocess.

Preparation, Dissolving and Mixing Tanks “Diso-Mix”

Dyestuff dosing and weighing

Dyestuff as powder, granulates or liquids can either be weighedand dosed manually using a weight scale (most common) or byan automatic dosing and dispensing system.

Stock Thickener

Stock thickener with all additional chemicals is prepared automa-tically with the SupraMix system and stored in a small holdingtank.Stock thickener is pumped to the dye mixing tanks by diaphragmpumps.

11. Color Preparation for Dyeing and Printing

Mixing tanks with integrated

dissolving function

• Touch Panel - user interface• Automatic level control • Integrated water heating with

temperature control • Mixer with different blades for

dissolving and mixing process• Speed control according to the

program and to the dye level• PLC control with bus interface• Tank sizes for 500, 1,000,

3,000 and 6,000 liters • Pre-assembled and wired


1) Dissolving of dyestuff

• Water is filled up to a cer-tain level (about 20% of thetotal volume)

• Water is heated up automa-tically to a certain tempe-årature (about 85°C/185°F).

• Dyestuff is added manually • Dyestuff is mixed and

dissolved in hot water

The tank is equipped with an Allen Bradley process controller with 4 basic functions and programs:

2) Mixing process

• The total amount of paste and the percentage of thickener is entered via Touch Screen

• Thickener and water arefilled up automatically to the pre-selected level - controlled by a level sensor

• Speed of mixer is also con-trolled by the level to avoid

that air is beeing mixed into the paste

• After a given time the mixer can be used as an agitator - to keep the pastein motion

• Automatic viscosity tester built into the tank is available optionally

3) Monitoring dye usage

• Depending on total amount and actual usage the con-trol unit can give a warning if remaining dye will not match the total consumptionover the planned productionrun.

Advantage of the Zimmer Diso-Mix System

• Less space needed (no second level for dissolving tanks)• Dyestuff can be dissolved in all mixing tanks (no waiting

time)• Operating panel is next to the mixing tank - operator can

actually see what happens• Automatic dissolving and mixing process• Easy to clean • Lower investment • Perfect compromise between investment cost and

productivityA simple version of dye kitchenswithout dissolving function, pro-cess control and with manual ope-rated valves is also available andsuitable for many applications.


4) Automatic washing of tank and mixer

• After print run is finished the tank can be washed almost fully automatically

• Remaining dye will be drained or emptied • Water is filled in automatically• Mixer starts with high speed - mixer and walls of tanks

are cleaned• Drain valve opens

Performance benefits • sharp, well-defined prints with

excellent colour-yield and brightness• superb resistance to colour-bleed • suitable for fine-jet printing without

blocking• wide pH usage range• compatible with all main dyestuffs• suitable for printing polyamide,

wool, cotton and modacrylic

Handling properties• excellent print paste storage stability

over time• instantaneous thickening of print

paste formulations• no additional surfactants or additives

necessary for thickening effect

Scott Bader’s expertise in inverse emul-sion technology established benchmarkstandards for pigment printing in theglobal textile printing industry for manyyears. Now, in partnership with Zimmer,that expertise has been adapted to thecarpet printing industry with Texipol67-5046.

Contact :[email protected] Tel : + 33 -3 22 66 27 88Direct Fax : + 44 -1933 666 51

Texipol 67-5046 has been specially designed for printing with ChromoJettechnology. It is a high efficiency, synthetic thickening agent, already insolution. Its environmental credentials are high. It has very low levels ofBOD (Biological Oxygen Demand) and COD (Chemical OxygenDemand). It is also suitable for use in ÖKO-TEX applications and iscompliant with TSCA legislation.

Scott Bader Company LtdWollastonWellingboroughNorthamptonshireNN29 7RL United Kingdom www.scottbader.com

Producers of inverse emulsion polymers for ChromoJet technology

Scott Bader is a rare breed in industry today – it is a totally independent producer. For eighty years this inde-pendence has been bringing benefits to its customers. Without the threat of merger or takeover customershave the confidence to establish reliable, long-term partnerships. Now Zimmer customers too can benefit.

12. Research & Development, Manufacturing


Hardware and software:

Harry Kapfinger & Holger Kudlich

The R & D department

Chromojet assembly: Marco Aufinger

Chromojet assembly

Installation at the customer’s:

Andreas Nothegger & Edgar Gittersberger

Chromojet MP assembly hall

Installation at the customer’s plant

12. Local Service, Customer Service, Leisure


Customer service and spare parts:

Gidi Steinbacher, Martin Lamprecht,

Hans Steindl

Great teamwork, also at leisure activities

Hiking in the nearby mountains

Sabine, Steffi, Luise ...

30+ trainees every year

Sales team:

Thomas Klöbl, Sabine Krimbacher,

Josef Guggenberger

Annual staff party

Mt. Wendelstein peak 1.854 m


Zimmer Machinery Corporation

Spartanburg, S.C. 29304P.O.Box 5561/USAT ++1 864 463 4352F ++1 864 463 [email protected]

Specially trained local technical

service, 24-hour-call-service,

modem connection service, external

local spare parts departments and

local sales agents are available in

most countries worldwide.

J. Zimmer Maschinenbau GmbH Kufstein

Eibergstrasse 2-8A-6330 Kufstein/AustriaT ++43 5372 64893F ++43 5372 [email protected]

J. Zimmer Maschinenbau GmbH

Klagenfurt

Ebentaler Strasse 133A-9020 Klagenfurt/AustriaT ++43 463 3848F ++43 463 [email protected]

Zimmer Service Centre of China

Room 907 & 910, #2 Building#988 Ping Liang RoadShanghai 200082, P.R. ChinaT ++86 21 5521 5402F ++86 5521 [email protected]

Zimmer Machinery Asia Ltd.

Unit 3, 8/F, Kwai Cheong Centre40-52 Kwai Cheong RoadKwai Chung, N.T., HongkongT ++852 2423 2355F ++852 2423 [email protected]

[email protected]

www.zimmer-austria.com

Zimmer - the Partner for the

Carpet Printing Industry

ChromoJet Printers for mats, carpet tiles, rugs, wall-to-wall carpets,blankets and artificial furs

ChromoJet-F Printer for high speed and multi-color print lines

RotaScreen - rotary screen printers

Entry Units with unrolling, J-box or accumulators, lint removal, pileraiser, pre-steamer, pivot guides

Horizontal Steamers with conveyors or rollers

Washing Units - shuttle washer, sandwich washer, twin-slot washer

Dryers - double impingement or throughflow dryers with conveyors ortenter frames

Roll-up and Plaiting Units

Supra-Mix - dosing and mixing of thickeners and chemicals

Color Kitchen - dissolving and mixing tanks, mixers and preparationequipment

Sample Equipment - ChromoJet sample printer, sample steamer anddryers, lab equipment, mixers

Specials - shuttle spray applicator, filter stations for gum recycling,dosing pumps

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