zimmer austria kufstein - textile testing, conference ... · mainly used in the fashion industry,...

DIGITAL TEXTILE CONGRESSCarpet & Textile Printing Systems

September 4‐5, 2014.

ZIMMER AUSTRIAwww.zimmer‐austria.com 1

www.zimmer‐austria.com www.zimmer‐kufstein.com

ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS

ZIMMER AUSTRIA | Kufstein

Digital Printing using VAT INKS!

SOLUTIONS FOR YOUR NEEDSBeyond simple applications, we also like to do things nobody else does!



ZIMMER AUSTRIA | MASCHINENBAU

Since 1874 ZIMMER has been in service to thetextile industry.

Setting milestones such as the first rotary screenprinter, the first carpet printer, the first digitalinkjet printer and many other innovations.

ZIMMER AUSTRIA developed a number ofspecial applications and machinery for the textileindustry that have changed the industriestremendously.

PIONEERING INNOVATIONSFOR MORE THAN 140 YEARS

INNOVATION QUALITY SERVICE






ZIMMER AUSTRIA

ZIMMER AUSTRIA Kufstein | Digital Printing Systems is the digital competence centre for textile, narrow fabric andcarpet printing machines as well as system supplier for carpet coating lines.

ZIMMER AUSTRIA Klagenfurt | Screen Printing & Coating Systems provides all screen printing and coating machines,as well as hot air dryers, heat treatment machines and loop steamers. The lines are adapted, designed andmanufactured according to the requirements of our customers.



ZIMMER AUSTRIA Inc.

SALES & SERVICE COMPANY

of J. Zimmer Maschinenbau GmbH

ZIMMER AUSTRIA Inc.

ZIMMER AUSTRIA Inc.PO Box 5561Spartanburg, SC 29304USA+1 (864) 4634352info@zimmer‐austria.com

www.zimmer‐austria.com






OUR BUSINESS SEGMENTS

DIGITAL SOLUTIONSFOR YOUR NEEDS

“Beyond simple applications, we alsolike to do things nobody else does!”

Textile Printing

Floor Covering

Narrow Fabrics

Digital Functionalization

Specialities



DIGITAL SPECIALITY PRINTING






• Uniforms and Workwear• Camouflage• Home Textiles• Technical Textiles

The better alternative to reactive and pigment inks

VAT INK PRINTING on CELLULOSIC FIBRES



To get 1g of Purple, approx. 10,000 dog whelks (purpursnails) where needed. Purpur dye was made for the first time in Crete, Greece, about 3500 years ago.

In 1907, Purpur was synthesized chemically for the first time.

In the middle ages, about 3750 ha was occupied in Germany with Indigo plants. About 300 kg of plant was giving 1 kg of Indigo. The Indigo plants in India gave about 30 times more dye, so the production of Indigo stopped in Europe around 1700.

in 1870, Adolf von Baeyer synthesized Indigo chemically for the first time.

WE ALL KNOW

Purpur

INDIGO






VAT DYES

THE PRINCIPLE OF VAT PRINTING

The VAT dye is printed in form of a pigment.

During the padding and steaming process, the pigments are transferred into a liquid form and enter the cellulose fiber. During the oxidizing step, the VAT dye is transferred back into its insoluble form.



VAT DYES

Mainly used in the fashion industry, especially for the Denim Industry.

The fastness properties of the Indigo types are limited.

As the Leuco compound is rather slow for fixation and is fixing only partly onto the fibre, a multiple step dying is needed.

‐> Problem in Digital printing!

INDIGOID VAT DYE ANTHRAQUINONE VAT DYE

The general fastness properties of the Anthraquinone VAT Dyes are much better compared to the Indigo types, and the Leuco compound of those dyes is fixing faster and fixates almost completely onto the fiber.






Dye Classes COMPARISON ‐ CONVENTIONAL & DIGITAL PRINTING

97% CONVENTIONAL PRINTING 3% DIGITAL PRINTING

• Average growth of digital printing is around 25% per year

• VAT prints represent 3% of total printed market• Todays digital printing volume is also only 3%

On which fibers could VAT dyes be used?

• Cotton, Flax, Jute, Bamboo, Hemp, Modal, Sisal, Rayon, Lyocell, …

• Certain shades also on Wool, Silk and Nylon



Product COMPARISON ‐ CONVENTIONAL & DIGITAL PRINTING

CONVENTIONAL PRINTING DIGITAL PRINTING

Mainly Pigment & Reactive Disperse (Sublimation + Direct)

Hometextile23%

33 billions m² 1 billion m²

65% CO, CV, Fibre blends 65% PES






VAT INKS COMPARED TO REACTIVE AND PIGMENT

for industrial printing on cellulosic textile constructions

REACTIVE INKS ARE LACKING• Fastness for multiple washing • Light fastness of pale shades ‐ especially red shades• Chemical resistance in finishing process• Fastness to chlorine treatments• Fastness to oxidizing wash detergents

PIGMENT INKS ARE LACKING• Fastness for multiple washing • Fastness to rubbing ‐ especially wet rubbing • Handle and drape ‐ especially with highly colored designs• Pretreatment needed for better quality• Penetration



FASTNESS COMPARISON – VAT, REACTIVE AND PIGMENT

for industrial printing on cellulosic textile constructions

Reactive Pigment VAT inks

High colour strength

Fastness at light (pale shades) >6

Fastness under rubbing dry

No crease marks

Soft handle

Fastness under chlorine

Fastness under dry cleaning






TYPICAL AND POSSIBLE APPLICATIONS FOR COLARIS.DIGITAL VAT PRINTING

HOME TEXTILES, UPHOLSTERY AND WINDOW FASHION

TERRY TOWELS ANDBATH ROBES

DENIM FASHION AND JEANS

WORKWEAR AND UNIFORMS

Whenever extreme light fastness, excellent crock fastness and a soft surface feel is needed.

Terry products and other hospitality items with deep colors, highest wash fastness and softest touch.

Already dyed denim could be overprinted with the high fastness standards.

Custom designed workwear, uniforms and camouflage patterns with highest wash and light fastness and a soft surface feel can be printed digitally.



REQUIREMENTS ON …






REQUIREMENTS ON …

… INKS• Jetability• Improved compatibility and stability• Improved open time• Improved stress resistance• Tighter drop forming performance• Drop speed, weight, flowability …



JETTEX INDANTHREN INKS

The digital VAT printing process has been developed by DyStar and ZIMMER AUSTRIA.

The goal is to make DIGITAL VAT printing available to the industry and to open up new opportunities for the high‐end printing industry. It is for sure that VAT dyes are in many cases the better alternative to reactive and pigment dyes when it comes to print on cellulosic fibers.






COLOR GAMUT OF VAT INKS

Jettex VAT CMYK + Orange + Green + Brown7 inks bulk proof tested – Strength, Fastness, Runability

Printed with ZIMMER AUSTRIA | COLARISequipped with FUJIFILM Dimatix StarFireTM

print head

COLOR GAMUT OF VAT INKS



REQUIREMENTS ON …







REQUIREMENTS ON …

… PRINT HEADS

• Circulation system • Repairable• Robust• Heads with different drop sizes

for different applications




PRINT HEAD SELECTION

FUJIFILM Dimatix StarFireTM print head

• Industrial design (coming from the ceramics industry)• 1024 nozzles per head (good compromise between cost and density)• 3 different head sizes with identical take up and drive system • “RediJet” ink circulation system • Integrated heating system • Base plate out of scratch‐proof Rhodium • Stable and precise droplet positioning even at large distance between head and printing substrate

• Repairable (change of individual components) due to modular design• Suitable for a broad pH range • Waveforms can be created by ZIMMER for inks and other special jetting fluids






COLARIS.PRINT HEAD

HIGH.PERFORMANCEindustrial inkjet print headsStarFireTM SG1024/SAStarFire TM SG1024/MAStarFire TM SG1024/LA

PRINT HEAD MODELS StarFireTM SG1024/SA StarFireTM SG1024/MA StarFireTM SG1024/LA

Number of addressable jets 1024 1024 1024

Print width per print head 64 mm 64 mm 64 mm

Nozzle spacing 0.0635 mm = 400 dpi 0.0635 mm = 400 dpi 0.0635 mm = 400 dpi

Waveform & fluid dependent drop size 12 – 35 pl at 20 kHz 30 – 75 pl at 18 kHz 75 – 180 pl at 12 kHz

Frequency up to 50 kHz up to 50 kHz up to 50 kHz

Operating mode Binary or multi‐step greyscale mode Binary or multi‐step greyscale mode Binary or multi‐step greyscale mode

Applications Light & medium fabrics i.e. fashion, home textiles, flags & banners, …

Heavy textilesi.e. velour, plush, terry products, …

Voluminous substratesi.e. carpet, …



PRINT HEAD REPAIR






REQUIREMENTS ON …


… PRINT HEADS





REQUIREMENTS ON …

… INKJET PRINTING SYSTEMS & PROCESS

• Reliable and stable process• Application driven software • Easy maintenance


… PRINT HEADS








THE TRADITIONAL PROCESS: 2 PHASES

COLARIS.VAT PRINTING PROCESS OFF‐LINE FIXATION PROCESS

Pre‐Coating with thickener to avoid color migration


COLARIS.INKJET PRINTING4 – 8 DyStar INDANTHREN inksoptional: Penetration Booster


Drying at about 110 – 130°CDrying at about 110 – 130°C

PADDINGusing Rongalit or Hydrosulfite


STEAMING at about 100 ‐ 105°C forabout 5 ‐ 20 min. depending on padding

orFLASH AGER at 120 ‐ 130°C for

about 1 ‐ 3 min.



about 1 ‐ 3 min.

WASHING ProcessRinsing, Oxidizing, Soaping, Rinsing


DRYING in a stenterDRYING in a stenter



THE 1‐PHASE PROCESS

COLARIS.VAT PRINTING PROCESS OFF‐LINE FIXATION PROCESS





Drying about 110 – 130°CDrying about 110 – 130°C





about 1 ‐ 3 min.



about 1 ‐ 3 min.




COLARIS.VAT PRINTING PROCESS

Pre‐Coating with thickener to avoid color migration & application of reduction

chemical e.g. Rongalit

Pre‐Coating with thickener to avoid color migration & application of reduction

chemical e.g. Rongalit




or FLASH AGER at 120 ‐ 130°C for

about 1 ‐ 3 min.


or FLASH AGER at 120 ‐ 130°C for

about 1 ‐ 3 min.









REQUIREMENTS ON …


• Reliability and stability• High resolution• Application driven software • Easy maintenance


… PRINT HEADS





REQUIREMENTS ON …

… INKJET PRINTING SYSTEM MANUFACTURER

• Innovative• High quality materials and manufacturing

process• Good support and service • Good know‐how of complete textile

and print process


• Reliability and stability• High resolution• Application driven software • Easy maintenance


… PRINT HEADS







ZIMMER AUSTRIA | SCREEN & COATING SYSTEMS

The target & strategy of the Technology Centre

R&D

Sampling

Workshop & Training

Conventions



COLARIS.SAMPLE PRINTER

Print size 120x120 cmNumber of colors 12, 6+6, 8+4, 4+4+4,..Printheads StarFireTM in any combinationInk supply 0.2 ‐ 2 literCirculation system YESHeating YESDegassing YES






www.zimmer‐austria.com | www.zimmer‐kufstein.com



ZIMMER AUSTRIAThomas KLOEBL

Sales Manager | ZIMMER AUSTRIA Kufstein+43 (0)664 548 68 83| t.kloebl@zimmer‐austria.com

CREATING SUCCESS STORIES40 YEARS OF DIGITAL PRINTING

zimmer austria kufstein - textile testing, conference ... · mainly used in the fashion industry,...

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