Preparation Of Printing Pastes
Type of specific formulation used depends on the fiber, the colorant
system used and, to some extent, the type of printing machine.
TvDicaZ Inmedients Used Include:

• Dyes or pigments

• Thickeners

• Binders, cross-linking agents

• Sequestrants

• Dispersing agents - surfactants

• Water-retaining agents (humectants)

• Adhesion promoters

• Defoamers

• Catalysts

• Hand modifiers

Types Of Printing Processes

Automatic Flat Screen Printing

A Approximately 17% of printed goods

B. Advantages

1. Largerepeats

2. Multiple strokes for pile fabrics

C. Disadvantages

1. Slow

2. No continuous patterns

Rotarv Screen Printing

A. Approximately 50% of printed goods

B. Advantages

1. Fast

2. Quick changeover of patterns

3. Continuous patterns

C. Disadvantages

1. Design limitations

2. Small repeats

Engraved Roller Printing

A Approximately 26% of printed goods

B. Advantages

1. High design capability

a. Finedetail

b. Multiple tones

C. Disadvantages

1. Copper cylinders very expensive

2. Not economical for short runs

3. Requires highly skilled workers

Heat Transfer Printing

A. Approximately 7% of printed goods

B. Advantages

1. High quality prints

2. Fewer seconds

3. Economical for short runs

4. Practically pollution free

C. Disadvantages

1. Slow

2. Primarily only for polyester

Case Studies for Textile Printing (11)

CASE STUDIES FOR TEXTILE PRINTING
CASE NO. 11
Description: Kemp Furniture used several process
modifications to reduce their overall waste volume. As
a furniture manufacturer, the traditionally used solventbased
inks to print wood grain on plywood and fiberboard.
Courses of Action:
With only minor changes in operating procedures, the
company substituted water-based inks for the solvent-based
inks.
Savings :
The net result of this initial change was to reduce
solvent waste by 30 - 40%. These waste solvents were
reused, where possible, to clean pumps and piping. This
was all accomplished with no major capital outlay. Offsite
recovery of solvent was used and this solvent reused
in processing.

Case Studies for Textile Printing

CASE STUDIES FOR TEXTILE PRINTING
CASE NO. 10
Description: Ellen Knitting Mills, a North Carolina
hosiery company, was discharging spent dye bath water to
a municipal sewer system. The water temperature of 130° F.
caused many problems for the sewer treatment system.
Courses of Action:
The company decided to purchase a heat reclaimation
system. This type system is generally only cost effective
if there is a sufficient flow of water at a high enough
temperature. The net result of this action was reduced
thermal pollution, reduced waste treatment costs and
recovery and reuse of energy.
Savings:
The company invested $100,000 in a heat recovery and
exhange system reducing the effluent temperature from 130°F
to 70°F. This removed heat was used to preheat incoming
feed water for dye tubs from 55°F. to 105°F. This
preheating operation alone saved approximately 52,000
gallons of fuel oil per year. Total payback for the system
was two years.

Case Studies for Textile Printing

CASE STUDIES FOR TEXTILE PRINTING
CASE NO. 9
Description: United Piece Dye Works is a textile dyeing
and finishing operation located in North Carolina. The
company because of its processing operations had a
problem with phosphorous containing materials in its
effluent.
Courses of Action:
The company was able to meet stringent discharge limits
on phosphorous by making chemical substitutions in their
production processes. Initially, a detailed chemical
analysis and evaluation of their processing was performed
to identify sources of phosphorous. Where possible, nonphosphorous
or non-phosphate containing chemicals were
substituted.
Savings:
Through this substitution, the use of hexametaphosphate
was reduced and the use of phosphoric acid was totally
eliminated. The level of phosphorous in the company's
effluent was reduced from 7.7 mg/liter to less than 1
mg/liter. United Piece Dye Works was able to meet these
effluent limits without any capital expenditure for
phosphorous removal or quality reduction in their products.