REACTIVE &
DISCHARGE PRINTS
By:-Sukhvir Sabharwal
Triburg ///
sukhvir.sabharwal.tit07@gmail.com
DISCHARGE PRINT TECHNIQUE
FLOW CHART
DYEING OF FABRIC
• RFD Fabric is dyed in the darkest base color
• PRINTING BY USING D...
REACTIVE PRINT TECHNIQUE
FLOW CHART
RFD PROCESS
• Fabric is processed till RFD stage . RFD process includes desizing / sin...
MACHINE OVERVIEW
sukhvir.sabharwal.tit07@gmail.com
SINGEING & DESIZING
• Singeing is done to burn the protruding fibres from the surface of fabric.
• Singeing improves appea...
sukhvir.sabharwal.tit07@gmail.com
Greige Fabric Inlet
sukhvir.sabharwal.tit07@gmail.com
Water Tub
sukhvir.sabharwal.tit07@gmail.com
Calendar Rolls( Steam Heated)
Flame is present at this place. It is passed tangentialy to the fabric surfacesukhvir.sabhar...
Desizing solution chamber
sukhvir.sabharwal.tit07@gmail.com
Fabric Collecting Trolley
sukhvir.sabharwal.tit07@gmail.com
CONTINIOUS BLEACHING RANGE( SCOURING
/ MERCERISING/BLEACHING)
• Scouring is done to remove impurities like dust / kitty / ...
Inlet for fabric
sukhvir.sabharwal.tit07@gmail.com
Scouring Area
Mercerizing / Bleaching Area
sukhvir.sabharwal.tit07@gmail.com
Mercerizing/ Bleaching Chambers
sukhvir.sabharwal.tit07@gmail.com
sukhvir.sabharwal.tit07@gmail.com
ROTARY PRINTING M/C
• One rotary print roll is used to print one color.
• Rotary m/c are available to print 10colors at on...
ROTARY PRINTING M/C
Printing Roll
Hydraulic Pressure Head
sukhvir.sabharwal.tit07@gmail.com
sukhvir.sabharwal.tit07@gmail.com
sukhvir.sabharwal.tit07@gmail.com
STEAMING M/C
• This m/c is used for fixation of printing colors by passing the fabric through
high temp.
• The temp. maint...
CLOSED STENTER
• This m/c is the heart of any dyeing/printing mill.
• Final width of fabric is adjusted by this m/c.
• Sof...
CLOSED STENTER
sukhvir.sabharwal.tit07@gmail.com
Mangle
Dye Tub
sukhvir.sabharwal.tit07@gmail.com
Width Controlling Unit
sukhvir.sabharwal.tit07@gmail.com
CONTINIOUS WASHER
• This m/c is used for Discharge & Procian prints.
• The fabric is washed to extract the residual color ...
CONTINIOUS WASHER
Fabric In
sukhvir.sabharwal.tit07@gmail.com
Washing Tanks
sukhvir.sabharwal.tit07@gmail.com
SANFORIZING M/C
• This m/c adjust the shrinkage in warp as well as weft direction. That’s why
it is also called zero zero ...
SANFORISING M/C
sukhvir.sabharwal.tit07@gmail.com
Steam Heated Rubbers
sukhvir.sabharwal.tit07@gmail.com
VARIABLE FACTORS IN DISCHARGE &
REACTIVE PRINT TECHNIQUE
1.) Mercerization --- This process is used to improve the absorbe...
WHY DISCHARGE PRINT IS TERMED AS
BLIND PRINTING
• The appearance of fabric during subsequent process of
printing / steamin...
FABRIC APPEARANCE AFTER
EACH STAGE FOR REACTIVE &
DISCHARGE PRINTING
sukhvir.sabharwal.tit07@gmail.com
DISCHARGE PRINT PROCESSES
DYED FABRIC AFTER PRINTING AFTER STEAMING
AFTER WASHING
sukhvir.sabharwal.tit07@gmail.com
REACTIVE PRINT PROCESSES
AFTER PRINTING AFTER STEAMING AFTER WASHING
sukhvir.sabharwal.tit07@gmail.com
sukhvir.sabharwal.tit07@gmail.com
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Printing-Reactive & Discharge print Presentation By Sukhvir Sabharwal

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Hi All,

Pls find PPT on reactive and discharge print which shows the difference to understand both print styles.

Hope this would help you !

Best,
Sukhvir

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Printing-Reactive & Discharge print Presentation By Sukhvir Sabharwal

  1. 1. REACTIVE & DISCHARGE PRINTS By:-Sukhvir Sabharwal Triburg /// sukhvir.sabharwal.tit07@gmail.com
  2. 2. DISCHARGE PRINT TECHNIQUE FLOW CHART DYEING OF FABRIC • RFD Fabric is dyed in the darkest base color • PRINTING BY USING DISCHARGING AGENT PRINTING BY USING DISCHARGING AGENT • Fabric is printed on rotary machine by using discharging agent(Rangolite). This chemical is mixed with color dyes • Discharging agent discharges the dyed base color & then color dyes fill up the discharged areas STEAMING • This process is used to fix-up the printed color. Controlled steaming procedure will results in better fastness of color. WASHING • This process is used to drain out residual color from the surface of printed fabric. On an average approx 30% of printed color depth is being washed out at this stage. STENTER & SANFORIZING • After washing fabric is being passed through stenter maching to apply softner & control the final width • Sanforising is used to control the final shrinkage of fabric by passing the fabric through heated rubber rollers/blanket. sukhvir.sabharwal.tit07@gmail.com
  3. 3. REACTIVE PRINT TECHNIQUE FLOW CHART RFD PROCESS • Fabric is processed till RFD stage . RFD process includes desizing / singeing / mercerization. PRINTING BY USING REACTIVE COLORS • Fabric is printed on rotary machine by using REACTIVE COLORS. These color particles have a tendency to penetrate well in to fibre structure STEAMING • This process is used to fix-up the printed color. Controlled steaming procedure will results in better fastness of color. WASHING • This process is used to drain out residual color from the surface of printed fabric. On an average approx 35-40% of printed color depth is being washed out at this stage. STENTER & SANFORIZING • After washing fabric is being passed through stenter machine to apply softener & control the final width • Sanforising is used to control the final shrinkage of fabric by passing the fabric through heated rubber rollers/blanket. sukhvir.sabharwal.tit07@gmail.com
  4. 4. MACHINE OVERVIEW sukhvir.sabharwal.tit07@gmail.com
  5. 5. SINGEING & DESIZING • Singeing is done to burn the protruding fibres from the surface of fabric. • Singeing improves appearance as well as pilling resistance. • Desizing is used to remove the starch from fabric surface. • Desizing process improved the absorption of fabric. sukhvir.sabharwal.tit07@gmail.com
  6. 6. sukhvir.sabharwal.tit07@gmail.com
  7. 7. Greige Fabric Inlet sukhvir.sabharwal.tit07@gmail.com
  8. 8. Water Tub sukhvir.sabharwal.tit07@gmail.com
  9. 9. Calendar Rolls( Steam Heated) Flame is present at this place. It is passed tangentialy to the fabric surfacesukhvir.sabharwal.tit07@gmail.com
  10. 10. Desizing solution chamber sukhvir.sabharwal.tit07@gmail.com
  11. 11. Fabric Collecting Trolley sukhvir.sabharwal.tit07@gmail.com
  12. 12. CONTINIOUS BLEACHING RANGE( SCOURING / MERCERISING/BLEACHING) • Scouring is done to remove impurities like dust / kitty / husk from the fabric. This process is done by running the fabric through boiled water. • Mercerizing is done to improve absorption of fabric. This is done by passing the fabric through NaOH( Sodium Hydroxide) at different concentration depending on the end shade required. • Bleaching is done to improve whiteness in the fabric. There are mainly 2methods of bleaching – – Half Bleaching – done by HOCL (Hypo Chloride) solution – Full Bleaching – done by H2O2 ( Per Oxide) Solution sukhvir.sabharwal.tit07@gmail.com
  13. 13. Inlet for fabric sukhvir.sabharwal.tit07@gmail.com
  14. 14. Scouring Area Mercerizing / Bleaching Area sukhvir.sabharwal.tit07@gmail.com
  15. 15. Mercerizing/ Bleaching Chambers sukhvir.sabharwal.tit07@gmail.com
  16. 16. sukhvir.sabharwal.tit07@gmail.com
  17. 17. ROTARY PRINTING M/C • One rotary print roll is used to print one color. • Rotary m/c are available to print 10colors at once. • Darkest color is printed first & lightest color at last. • Printing roll pressure is controlled by hydraulic pressure head. • Printing color are pumped in to the rotary rolls through pipes. • The color is then spread over on the fabric through blade placed inside the roll. • The fabric is then forwarded to the heated segment maintained @ 85- 90degree where the color are dried up. • The fabric is then collected at trolley placed at the end of rotary m/c sukhvir.sabharwal.tit07@gmail.com
  18. 18. ROTARY PRINTING M/C Printing Roll Hydraulic Pressure Head sukhvir.sabharwal.tit07@gmail.com
  19. 19. sukhvir.sabharwal.tit07@gmail.com
  20. 20. sukhvir.sabharwal.tit07@gmail.com
  21. 21. STEAMING M/C • This m/c is used for fixation of printing colors by passing the fabric through high temp. • The temp. maintained is approx 100-150degrees for cotton fabrics & 150- 200degree for polyester. • Speed of m/c & heat exposure time is decided on the basis of print color coverage. For Ex. -- For blotch prints with maximum coverage, m/c is kept as slow speed so that the fabric can get more time for heat exposure. sukhvir.sabharwal.tit07@gmail.com
  22. 22. CLOSED STENTER • This m/c is the heart of any dyeing/printing mill. • Final width of fabric is adjusted by this m/c. • Softener is being applied by his m/c. • This m/c consists of 2parts – Dyeing tub with mangle – Heated chambers ( 8-12) sukhvir.sabharwal.tit07@gmail.com
  23. 23. CLOSED STENTER sukhvir.sabharwal.tit07@gmail.com
  24. 24. Mangle Dye Tub sukhvir.sabharwal.tit07@gmail.com
  25. 25. Width Controlling Unit sukhvir.sabharwal.tit07@gmail.com
  26. 26. CONTINIOUS WASHER • This m/c is used for Discharge & Procian prints. • The fabric is washed to extract the residual color from the surface of fabric. • This m/c consists of several bath tubs containing cold & hot water. • Water is changed after every 1000mtrs to minimize the tinting of dark colors on to the light colors. sukhvir.sabharwal.tit07@gmail.com
  27. 27. CONTINIOUS WASHER Fabric In sukhvir.sabharwal.tit07@gmail.com
  28. 28. Washing Tanks sukhvir.sabharwal.tit07@gmail.com
  29. 29. SANFORIZING M/C • This m/c adjust the shrinkage in warp as well as weft direction. That’s why it is also called zero zero m/c means zero shrinkage in both the directions. • The wet fabric passed b/w steam heated rubbers. • This m/c has the same effect as that of steam iron. sukhvir.sabharwal.tit07@gmail.com
  30. 30. SANFORISING M/C sukhvir.sabharwal.tit07@gmail.com
  31. 31. Steam Heated Rubbers sukhvir.sabharwal.tit07@gmail.com
  32. 32. VARIABLE FACTORS IN DISCHARGE & REACTIVE PRINT TECHNIQUE 1.) Mercerization --- This process is used to improve the absorbency & dischargability of fabric. Any slight variation in caustic application will result in bulk lot variation. 2.) Steaming – This process is used for fixation of color. Steam is being applied in a closed chamber. To have even results the effect of steam should be even at all points but it is really impossible to maintain the same level of steam at all areas hence we get more bulk variation. 3.) AIRING – The fabric after printing is left for airing to have better development of colors. The surrounding environment does have an impact of final color fixation & hence the final color shade changes. Hence it is recommended not to perform a discharge/reactive print in high humidity or rainy season . 4.) Washing -- This process is used to drain out extra color from the fabric surface. As a rule, 1000ltrs of fabric is being used for 2000mtrs fabric & then fresh water is being used. Since the superficial color gets mixed in the water, hence migration of darker colors on lighter colors happens at this stage. In case of black & white print, this process becomes more crucial since black color migrates on to white color. Moreover, since a 2000mtrs bulk lots is washed at once, the maximum size of bulk lot is 2000mtrs only. sukhvir.sabharwal.tit07@gmail.com
  33. 33. WHY DISCHARGE PRINT IS TERMED AS BLIND PRINTING • The appearance of fabric during subsequent process of printing / steaming & washing changes drastically. This is being shown in subsequent slides • We can see the final appearance after washing/finishing only • Hence we can’t determine exactly the final product outcome due to several variable factors as advised in earlier slide. sukhvir.sabharwal.tit07@gmail.com
  34. 34. FABRIC APPEARANCE AFTER EACH STAGE FOR REACTIVE & DISCHARGE PRINTING sukhvir.sabharwal.tit07@gmail.com
  35. 35. DISCHARGE PRINT PROCESSES DYED FABRIC AFTER PRINTING AFTER STEAMING AFTER WASHING sukhvir.sabharwal.tit07@gmail.com
  36. 36. REACTIVE PRINT PROCESSES AFTER PRINTING AFTER STEAMING AFTER WASHING sukhvir.sabharwal.tit07@gmail.com
  37. 37. sukhvir.sabharwal.tit07@gmail.com

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