The document details the flocking process, which involves applying fine fiber particles onto surfaces to enhance aesthetics, functionality, and texture. It describes various methods of flocking, including electrostatic application and traditional adhesives, along with the types of materials used, such as natural and synthetic fibers. Additionally, it highlights the applications of flocking in industries like textiles and automotive, as well as the resurgence of interest in flocking techniques for decorative purposes.

1. Prepared By:
MD.AZMERI LATIF BEG
ID: 142-32-257
Course Title: Apparel Wash, Dyeing &
Finishing.
Course Code: AWF-514
M. Sc in Textile Engineering
Department of Textile Engineering

2. Flocking is the process of depositing many small fiber
particles (called flock) onto a surface. It can also refer to the
texture produced by the process, or to any material used
primarily for its flocked surface. Flocking of an article can be
performed for the purpose of increasing its value in terms of
the tactile sensation, aesthetics, color and appearance. It can
also be performed for functional reasons including insulation,
slip-or-grip friction, and low reflectivity. Besides the
application of velvety coatings to surfaces and objects there
exist various flocking techniques as a means of color and
product design. They range from screen printing to modern
digital printing in order to refine for instance fabric, clothes or
books by multicolor patterns. Presently, the exploration of the
flock phenomenon can be seen in the fine arts.
Flock Printing

3. These types of printing technique consist of the application of
flock (very short fiber) to the surface of a fabric by means of
an adhesive. The flock may be contained in the adhesive
paste, may be dusted onto it, or applied electrostatically to
hold it erect. This is used to print various small designs onto
the fabric, such as dots and figures, especially on light-weight
or sheer fabric.
Flocking is defined as the application of fine particles to
adhesive coated surfaces. Nowadays, this is usually done by
the application of a high-voltage electric field. In a flocking
machine the "flock" is given a negative charge whilst the
substrate is earthed. Flock material flies vertically onto the
substrate attaching to previously applied glue. A number of
different substrates can be flocked including; textiles, fabric,
woven fabric, paper, PVC, sponge, toys, automotive plastic.

4. A diagram of flocking texture
The majority of flocking done worldwide uses finely cut
natural or synthetic fibers. A flocked finish imparts a
decorative and/or functional characteristic to the surface.
The variety of materials that are applied to numerous
surfaces through different flocking methods create a wide
range of end products. The flocking process is used on items
ranging from retail consumer goods to products with high
technology military applications.

5. 4/18/2015 5
Flock Printing
 Tiny particles of fiber are made to adhere to a fabric surface in
conformance to a particular design. Rayon and nylon fibers are
typically used for flocking.
 The ability of flocked fibers to withstand dry cleaning and/or
laundry depends on the adhesive. Adhesives with excellent
fastness to cleaning processes are used.
Elegant appearance
A flock print has a velvety, fuzzy surface. The foil (0.5 mm) is
somewhat thicker than flex, which causes the design to appear
slightly elevated from the apparel and results in the plush feel. The
colors have a soft glow to them.

6. Flock Print process
• This process involves
printing of glue on the
fabric first, applying the
fiber flock on the gel
printed by keeping the
fabric on special table
(electro statically
charged).
• It requires a little high
time for curing than
normal prints. 120
seconds at 160C will be
sufficient for curing.

7. Printing technique consisting of the application of flock (very
short fiber) to the surface of a fabric by means of an adhesive.
The flock may be contained in the adhesive paste, may be
dusted onto it, or applied electrostatically to hold it erect. Used
to print various small designs onto the fabric, such as dots and
figures, especially on light-weight or sheer fabric.
The foil (0.5 mm) is somewhat thicker than
flex, which causes the design to appear
slightly elevated from the apparel and results
in the plush feel. The colors have a soft glow
to them.
Flock Printing technique

9. Flock Fibres
Flock can be made from natural or synthetic materials such as cotton,
rayon, nylon and polyester. There are two types of flock - milled and
cut. Milled flock is produced from cotton or synthetic textile waste
material. Because of the manufacturing process, milled flock is not
uniform in length, and can vary from fine (0~ - 0.5 mm) to coarse (0.4 -
1.1 mm). Cut flock is produced only from monofilament synthetic
materials. The cutting process produces a very uniform length of flock.
Lengths can be obtained from 0.3 - 5.0 mm and 1.7-22 dtex in diameter.
(One dtex is the measurement of a fibre that weigh; one gram per 10,000
meters of length.) The fineness of the flock, length of fibres and
adhesive coating density determine the softness of the flocking. It should
be noted however, that fine or short flock is difficult to work with, since
it has a tendency to ball-up during processing. Milled cotton flock has
the advantage of being the lowest in cost and the softest, but has the least
abrasion and wear resistance. Rayon is a little bit better on wear
resistance and nylon is the best. For cut flock, rayon is the least
expensive with the least wear resistance.

10. Cut nylon is the best grade of flock and produces a good feel, but is also
the most expensive. Cut polyester is basically used for industrial
applications such as automobile window seals, glove compartments, and
roofing. Besides cutting or milling, flock manufacturing includes several
other steps. After cutting, the flock is cleaned of oils that accumulated
during processing. It is vat dyed to any number of colours, and then
chemically treated to enable the fibres to accept an electrical charge.
Since the fibres are all dielectric, a certain amount of conductivity must
be present for electrostatic flocking process to occur. When the process
is complete the fibres are spin dried and then oven dried to a specific
moisture content. Note that flocking fibres are never totally dried, since
moisture content adds to their conductivity. Finally, the flock is
packaged in moisture proof bags that maintain proper humidity.
According to end use flock two types
Stuffing flock(use for upholstery)
Coating flock(cut or ground fibers used as a surface on fabric by
adhesive.)

11. Flocking
In short, the flocking process involves applying short
monofilament fibres, usually nylon or rayon, directly on to a
substrate that has been previously coated with an adhesive. The
diameter of the individual flock strand is only a few thousandths of
a centimetre, and ranges in length from 0.25 - 5 mm. Adhesives
that capture the fibres must have the same flexibility and resistance
to wear as the substrate. The process uses special equipment that
electrically charges the flock particles causing them to stand-up.
The fibres are then propelled and anchored into the adhesive at
right angles to the substrate. The application is both durable and
permanent. Flock can be applied to glass, metal, plastic, paper or
textiles. Flock design applications are also found on many items
such as garments, greeting cards, trophies, promotional items, toys
and book covers.

12. Flock printing principle
For flock printing the fabric to be printed should smooth and as
compact as possible.
Step-1
Application of adhesive: Adhesive is applied to fabric surface by
squeezer, roller, screen or spray methods. Synthetic resin can be
serve as the best adhesive.
Recipe:
Paralac 67----40 parts
Paralac 11----10 parts
White spirit--34 parts
China clay---15 parts
Lead napthilate(3% solution)-0.8 parts
Cobalt(8% solution)—0.3 parts
Water--------------X parts
Step-2
Flock application: (Can be flat/right angle to the fabric surface)
Step-3
Drying: Drying condition depends
on particular bonding agent.
Drying carried at 70c for 3-8 min.
For apparel steam heated tunnel
is suitable.
Step-4
Final treatment: Excess flocks
from unprinted areas are
removed by brushing and
mechanical suction unit.

14. The Flocking Process
The process of flocking is fairly simple and easy. First a suitable adhesive is
applied to the surface to be flocked. The flock is then applied, penetrating the
surface of the adhesive to create the desired velvet finish.
Electrostatic flock applicators charge the flock particles which are then
attracted to the grounded surface that is to be flocked. Unlike puffer or blown
application methods which merely sprinkle a flock layer onto the surface,
electrostatic application ensures that the fibres all end up standing at right
angles to the surface resulting in a velvet finish.
Electrostatic flocking is used extensibly in the automotive industry for coating
window rubbers, glove boxes, coin boxes, door cards, consoles, and
dashboards. Rally cars usually have their dashes flocked to reduce reflections
and to provide an as new finished to a modified dash.
Flocking is proving successful in a number of artistic ventures including the
decoration of jewellery, ceramics and pottery.
Using suitable adhesives flock can be applied to an endless range of materials
including plastic, metal, wood, rubber and fiber glass.

15. Detailed Insight
Consumers are always looking for something different and unusual. Suppliers seek
the same thing - a special item or product that will increase their market share or
generate new business. An example of this might be the recent popularity of mixed
media garments in the marketplace. Developing something different is always a top
priority, then, and is the driving force behind the recent resurgence of printer
interest in learning about flocking.
Flocking for decoration is not new, of course; similar methods were used in the
Middle Ages to attach fibre dust to sticky surfaces. It was in the 1970s, however,
with the advent of improved technologies and adhesives, that flocking became a
popular decoration method. Then, in the 1980s and early 1990s the popularity of
flocking faded away and few printers used the process. Even so, while flocking is
not the most widely used decorating process, nor is it a well known decorating
technique, the average person is aware of its velvet or suede feel.
Over the last several years, however, inquiries about the process have begun to
increase, and flocking is once again in demand as a decorating method. Even
though flocking may not be most decorators' first choice process at present, it is
used widely in many industrial applications. Flocked surfaces reduce water
condensation, act as good thermal insulators, and have been used in the
automotive industry for years for such items as glove compartment boxes, door
mouldings and window trim.

16. Application Methods
Decorative flocking is accomplished by using one of four
application methods: electrostatic, beater bar/gravity, spraying and
transfers.
The electrostatic method is perhaps the most viable flocking
method, especially for the printer doing more than an occasional
flocking job.
Flocking material can also be sprayed using an air compressor,
reservoir, and spray gun similar to spraying paint. The resulting
finish using this method is similar to a thin felt coating, as most of
the fibres will be lying down in the adhesive. It is primarily used
when large areas require flocking. It is an untidy process, because
some of the flocking fibres become airborne.
Flocking is also applied by printing an adhesive on to a substrate,
and then rapidly vibrating the substrate mechanically, while the
flock fibres are dispensed over the surface.

17. Flock application by the
vibration method.
Flock application by the
electrostatic method.

18. The vibration promotes the density of fibres, which is critical to good
fibre coating, and causes the flocking fibres to adhere to the adhesive
and pack into a layer. This process is called a beater bar or gravity
flocking system and is basically a mechanical process. With this
process the flocking fibres are randomly adhered to the surface of the
substrate, and each fibre adheres to the adhesive at a different depth,
creating an irregular flocked surface. Since the fibres adhere to the
surface of the adhesive, rather than penetrate or imbed in it, some
fibre shedding occurs. Loose flocking fibres generated during
production also have a tendency to migrate, so many of these systems
are installed in a separate area to prevent fibre contamination of the
shop.
The most successful method to ensure a good dense coverage is a
combination of electrostatic flock application with the use of beater
bars to help increase the density of the coating.

19. Adhesives
A wide variety of flock adhesives are available, both single part
and two-part catalysed systems. Adhesives are generally water or
solvent based. Some are air drying, others temperature or
catalyst curing. Adhesives are usually applied by brush, roller,
spray or screen printing.
Flock Binder
Chemical: Acrylic Emulsion
Appearance: Milky White liquid
High Quality Flocking binder. Adhesives gives very soft and
silky Feel.
Flock Binders that are available in different shades and colors.
It finds application in textile industry and used as an adhesive
for the lamination of film to paper/fabric. Flock Binder is well
known for its long lasting features and useful for variety of
purposes.

20. Example:-
K-87 is a self-crosslinking acrylic emulsion which combines softness and
resiliency with durability to washing and dry cleaning. Cured films of K-
87 exhibit superior ultraviolet light resistance. To achieve durability
from K-87. Catalysts are not needed. Due to its various properties, it
makes itself ideal for application.
Indofil is very well known for flock binder in India & Bangladesh
Indofil FBSV
: premium flock binder
Indofil FB SV plus
: GOTS approved flock binder
Indofil SVM 49
: Regular flock binder
Indofil K-87
: Premium flock binder for special requirements
Indofil NFBS
: Flock binder

21. Screen Print of Adhesives
Many of the adhesives have the consistency of plastisol ink. Care should be exercised to
select a stencil emulsion or film that is compatible with the adhesive to be printed.
Proper application of the adhesive is the most important part of the process. A very
heavy deposit of adhesive is required, but at the same time the adhesive should not be
'squeegeed' through the substrate. Care should also be exercised not to apply a thin
coating. Less adhesive does not give proper adhesion characteristics for the fibres,
which will result in low wear resistance. In order to achieve the proper deposit of
adhesive, the screen should be made from a 24 to 43 threads/cm (60 to 110 threads/inch)
monofilament mesh. Tension should be at 20 N/cm. Extra face coats of emulsion on the
print side of the screen may be required for mesh counts greater than 36 threads / cm (96
threads/in). Printing should be off-contact, using a 65 durometer ball-nose squeegee. If
you experience difficulty getting the proper coverage, do not thin the adhesive to make
it more printable. This will only create a thinner deposit by allowing the adhesive to
soak into the substrate. A better solution is to slow the squeegee stroke down to allow
the adhesive time to flow through the screen and on to the substrate. The flock adhesion
can be tested by subjecting the substrate to the standard textile wash test. If the flocking
fibres come loose or fall off, the adhesive may be too thin or the adhesive was
improperly cured. If the adhesive is properly applied, then the curing temperatures
should be adjusted until the substrate passes the wash test. This is the only safe way to
ensure proper curing of the adhesive.

22. Electrostatic Flocking of Textiles
Electrostatic flocking equipment for T shirt and other textiles is available in
three configurations: an automatic carousel for multicolour flocking, a single
station flocking unit that usually attaches to one station of a garment press, or
a portable hand-held unit for lower volumes. The cost of the equipment varies
from hundreds or a few thousand pounds for hand-held units to tens or
hundreds of thousands of pounds for automatic multicolour systems.
All of the equipment operates using the same basic procedure, and is explained
by a law of physics stating that opposing electrical charges attract each other.
In flocking, the electrical charge is generated by the use of two electrodes: a
high voltage, direct current grid connected to a power generator, and a
grounded substrate. An electrostatic charge is generated that propels the fibres
at a high velocity on to the adhesive coated substrate. This causes the flocking
fibres to penetrate and imbed in the adhesive at right angles to the substrate.
This forms a high density uniform flock coating or layer. Controlling the
electrical field by increasing or decreasing either the applied voltage or the
distance between the electrodes and the substrate controls the speed and
thickness of the flocking.

23. Multi colour flocking technique
For high level flock prints, multi colour flocking is desired.
There are several possibilities:
a) Flocking and drying of one colour, then flocking of the second colour
next to it (only possible with simple motifs, very time consuming).
b) Flocking of one colour onto the entire motif space, drying, then flocking
of the second colour onto the already existing flock layer, etc. (very time
consuming, flock onto flock is not very stable and the flocked area is stiff).
c) Textile printing of several colours and flocking of the last colour only (this
can create some very interesting effects).
d) Multi colour flock transfers (see special description).
e) MC-technique. Here, the adhesive is printed in form of the entire motif
and the flock is applied into the adhesive colour after colour through a
screen stencil (fabric 15 S, metallized polyester screen. Very nice motifs are
achieved by this method. However, a lot of equipment is necessary as a
carousel is recommended to have the individual screens fixed in exactly the
same distance of the 1.1 fold flock length suspended freely).

24. Multicolour flocking equipment has one print station for
applying the adhesive and multiple stations for applying the
flock. It uses a flat metal screen that is coated with an
emulsion and exposed with each of the design elements, the
same as it would be for screen printing. The flock is placed on
the metal screen, which acts as the high voltage electrode, and
a rotating brush precisely dispenses the flocking material.
When the screen is lowered to the proximity of the adhesive
coated substrate, the flocking fibres are propelled into the
adhesive, as determined by the stencil on the metal screen.
Since the electrostatic field strength is controlled, and because
the metal screen and the adhesive-coated substrate are brought
close together, the flocking material is prevented from
attaching to the adhesive except where the stencil is located,
regardless of the size of the adhesive coated substrate.

25. Hand held units the hand held units are comprised of a metal plate, a
generator and a flocking head. The metal plate must be grounded, and
it can be placed where convenient. It is the equivalent of the platen on
a textile press. The generator creates the electrostatic charge, and is
wired to a canister that contains the loose fibres. A metal screen is
mounted halfway inside the canister opening. The open end of the
canister is then passed over the adhesive coated substrate, drawing
flock fibres from the canister through the screen. The electrostatic
charge propels the fibres toward the grounded metal plate. The
adhesive coated substrate intercepts the fibres and flocking occurs. The
substrate is then cured in a conventional dryer, and the loose fibres are
removed by shaking, vacuuming or by using compressed air. Operation
of these units requires a degree of skill to obtain the desired results. If
the flocking head is held too far from the substrate poor coverage of
flocking fibres will occur.

26. The operator must also hold the unit perpendicular to the
substrate to prevent the flocking fibres from imbedding in the
adhesive at an angle other than perpendicular to the
substrate. Hand held units are also messier than automatic
systems and leave behind more fibres.
Curing the flocking is also an area that needs to be
investigated. Since few screen printers use water-based
adhesives, they may not have the proper curing equipment.
Water-based adhesives require the use of dryers that have
multiple independent heating zones with changeable air flow
rates. Even plastisol and catalysed adhesive may require
additional time to fully cure.

27. Application Environment
Having a controlled atmosphere for flocking operations is
generally regarded as another essential ingredient for
success. Ideally, the flocking area should have a relative
humidity of 60% and a temperature of 20C (68F). A small
variation in temperature or a change in the percentage of
relative humidity can result in a 3 to 4 factor change in the
conductivity or electrical sensitivity of the flock and the
substrate. These changes will have an adverse affect on the
process, and will result in flock balling, reduced adhesion and
density of the flocking, and an excessive use of flock. Flocking
fibres are very sensitive to humidity and temperature
conditions.

28. When a new batch of flock fibres is opened, the fibres will
give off or receive moisture based on the surrounding
environment. Less than 30% relative humidity in the
production area will lead to fibres that won't accept a charge.
Relative humidity in excess of 65% causes the flock to stick
together and flow poorly through the metal screen or plate.
For best results the flocking operation should be located in an
atmospheric controlled room. As stated earlier, in the
adhesives section, to ensure that your flocked designs have
received a proper cure, sample prints should be subjected to
the standard textile wash test.

29. Flocking Machines & Flocking Equipment
M&R’s Machine company invented flocking machines and
accessory flocking equipment simplify the application of
screen printing flock and the cleanup of excess T-shirt
flocking material. M&R flockers make it easy to add tightly-
registered multi-color T-shirt flocking capability to most
M&R automatic textile presses. They’re activated by the
print carriage and they’re compatible with M&R’s print-
start/print-finish feature, M&R’s patented Optical No-Shirt
Detector, and M&R’s Skip-Shirt foot pedal. Unlike some
competing T-shirt flocking machines, M&R flockers do not
require printhead removal.

30. Use:
A highly reliable and affordable device suitable for the
flocking of especially small-lot products, textiles, small items,
interior accessories, and the like.

31. Flocking is a value-added alternative decorating method for
achieving that unusual look. It only costs slightly more than
producing a standard screen print, and in conjunction with
textiles, it is certainly less expensive than embroidery. Also
with the advanced state of adhesive technology nearly any
material can be flocked, making it easy to add new products to
your textile production capabilities. Wallpaper, greeting cards,
mouse pads, book and album covers, and posters can all be
flock printed. The successful use of electrostatic flocking
depends on tight control over the process and the
environment. Detailed production records should be kept, so
the process can be repeated. Retention of production samples
is also an important factor for repeat jobs, product reliability,
and quality control information. While the process requires
the use of special equipment, with practice a quality product
can be produced.

32. Conclusion
Flocking is a value-added alternative decorating method for
achieving that unusual look. It only costs slightly more than
producing a standard screen print, and in conjunction with
textiles, it is certainly less expensive than embroidery. Also with
the advanced state of adhesive technology nearly any material
can be flocked, making it easy to add new products to your
textile production capabilities. Wallpaper, greeting cards, mouse
pads, book and album covers, and posters can all be flock
printed. The successful use of electrostatic flocking depends on
tight control over the process and the environment. Detailed
production records should be kept, so the process can be
repeated. Retention of production samples is also an important
factor for repeat jobs, product reliability, and quality control
information. While the process requires the use of special
equipment, with practice a quality product can be produced.

33. Reference:
http://www.flocking.biz/process.html
http://www.indiamart.com/classic-prints/textile-t-shirt-
printing-services.html
http://www.flocking binder.biz/process.html
http://www. Textile flockung_e/flock motif.html
https://www.spreadshirt.com/help-c1328/
http://impressions.issshows.com/screen-printing-
process/Flock-Printing-A-Closer-Look-
8287.shtml#sthash.upROHSOS.dpuf
http://www.garmentprinting-120202065211-phpapp02