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.

Case Studies for Textile Printing (8)

CASE STUDIES FOR TEXTILE PRINTING
CASE NO. 8
Description: RJR Archer, Inc. is a paper printing
operation. The company was having a great deal of
problems with air emissions from its printing presses.
Courses of Action:
RJR Archer installed a carbon adsorption system to
capture and recover 98% of the solvents lost to the
atmosphere from drying ovens. This amounted to an average
of 2,655 gallons per day. This solvent could be either
reused or sold. By properly recirculating air exhaust from
its drying ovens before distillation, the size of the
system was smaller than originally predicted.
Additionally, all inks formulations were reviewed and
reformulated using a maximum of two solvents per blend,
therefore increasing the recovery system efficiency.
Savings:
RJR Archer saves over $6,300 per day in solvent costs.
The payback for the $4.3 million recovery system was 2.5
years. After payback, RJR Archers estimated an annual
$1.7 million net cost savings.
Air emissions are also very important to a number of
textile printers.

Case Studies for Textile Printing (7)

CASE STUDIES FOR TEXTILE PRINTING
CASE NO. 7
Description: Rexham Corp. prints product labels using
alcohol/acetate based formulations using flexographic
printing techniques.
Courses of Action:
The company was able to reduce its waste generation
through process modification. Rexham substituted water
based inks for the traditional solvent based materials.
The net result was to reduce the quantity of solvent waste
generated and the quantity of solvent released to the
atmosphere. However, gloss finish labels could not be
printed this way. There was also a net decrease in
printing speed using the water-based inks.
Savings:
This modification did not require Rexham to incur
any large capital costs; however, some operator retraining
was required. Because the company also purchased an onsite
distillation system for solvent recovery for $16,000,
Rexham Corp. saves $15,000 per year in virgin solvent costs
and $22,800 per year in waste disposal costs. Total payback
for the process modifications and solvent recovery
systems was 5 months.
As can be seen, this example relates directly to many
textile printing operations.

Case Studeis for Textile Printing (6)

CASE STUDIES FOR TEXTILE PRINTING
CASE NO. 6
Description: American Enka Co. (now BASF) produces nylon
yarn. Isopropyl alcohol was used as a solvent for a
fatty amine. Previously the company employed an outside
firm for the distillation and reuse of solvent. Average
solvent losses were 15% with some as high as 40%. The
solvent was also aften contaminated and required analysis
before reuse.
Courses of Action:
The company purchased a used distillation system for
$7,500.00 Some modifications were made to the unit for
use with their product.
Savings:
Initially this resulted in a $90,000.00 per year
savings over their previous contract fees. They also
obtained a much superior recovered solvent at a 90%
efficiency rate. They now use far more of the recovered
alcohol and also utilize the still bottoms as an asphalt
emulsifier in another product line. Total payback for
the project was approximately one month.
This project also relates to solvent recovery and
reuse possible by textile printing operations.

Case Studies for Textile Printing (5)

CASE STUDIES FOR TEXTILE PRINTING
CASE NO. 5
Description: Lenoir Mirror Co. uses xylene solvent in
equipment cleanup.
Courses of Action:
The company reduced their waste costs by recovering
and reusing spent solvent on-site. Approximately 95%
solvent was recovered by distillation and still bottoms
are sent to an incinerator.
Savings:
Lenoir Mirror saves over $5,000 per year in material
and disposal costs. Total system payout will be thirteen
months.
This overall case relates to solvent recovery in
printing from screen and machine cleanups.

Case Studies for Textile Printing (4)

CASE STUDIES FOR TEXTILE PRINTING
CASE NO. 4
Description: Thiele - Engdahl, Inc. uses printing inks.
In equipment cleanup the company uses isopropyl acetate.
Courses of Action
Thiele-Engdahl uses solvent twice for cleanup before
recovery and reuse. The solvent is recovered on-site
using batch distillation. Distillation bottoms are sent
off-site for disposal.
Savings:
Before the distillation system the company sent 5,000
gallons of used solvent to off-site disposal every 45 days.
Since reclaiming and reuse reduce both the volume of waste
and the volume of virgin solvents purchased, significant
savings result, paying for the distillation system in 2
years.

Cae Studies for Textile Printing (3)

CASE STUDIES FOR TEXTILE PRINTING
CASE NO. 1
Description: American Colors coats or prints on fiberglass.
Waste acetone is generated during the coating or printing
process.
Courses of Action:
(1) Waste acetone is distilled and recovered at
approximately a 70% rate. This reclaimed solvent is used
in equipment cleanup.
(2) The volume of solvent has been reduced by process
modifications, especially going from light to dark coatings.
This yields an overall reduction in cleanup waste.
Savings:
American Colors cut production costs by reducing volumes
of waste solvent and reclaiming what solvent waste was
generated. The net savings were many thousands of dollars
per year.

Case Studies for Textile Printing(2)

CASE STUDIES FOR TEXTILE PRINTING
CASE NO.2
Description - PCA International, Inc. is a color portrait
processing firm. PCA has undertaken a number of projects
to recover and recycle process waste especially silver
recovery.
Courses of Action:
(1) An electrolytic recovers silver from the color
negative film fixer solutions. The process results in a
96% reuse of the fixer solutions.
(2) Color developer is regenerated using an ion
exchange system. Total processing results in an 84%
recovery of the color developer solution.
(3) Spent bleach solutions are recovered and
regenerated by chemical additions, attaining 90% reuse
capability.
Savings:
PCA saves over $1.1 million each year in reusing
process solutions. Silver recovery adds another
approximate $800,000 per year.
As can be seen, this study easily relates to the
photographic processes used in textile printing screen
design and manufacture.

Case Studies for Textile Printing (1)

CASE STUDIES FOR TEXTILE PRINTING
CASE NO. 1
Description - A survey of dyes in the mid 1970's showed
that 95% of the capper in an N.C. company's effluent
originated from 13 dyes. They were:
Dye
Belamine F Red 3BL
Belamine B Blue LT
Pyrazol F Violet MXD
Solantine Brown BRL
Atlantic Blue 8 GLN-K
Atlantic Resinfast Blue 2R
Sirius Supra Turquoise LG
Superlitefast Blue 2GLL
Direct Navy OFS
Belamine Red 3BL
Solophenyl Brown BRL
Fastolite Blue L
Atlantic Black NR
Percentage Cu Content
4.00
3.68
3.00
3.00
2.70
2.50
2.29
1.00
0.70
4.00
3.00
2.70
1.50
All of the previous dyes have copper as a part of the
dye molecule structure.
Possible Courses of Action:
(1) Substitute for metal containing dyes with nonmetal
dyes.
(2) Insure maximum fixation of dye by optimizing
all processing parameters such as time and temperature of
fixation, pH, salt concentration, and auxillary chemicals
content.
In this case, direct dyes with non-metal content were
substituted where possible, therefore, reducing the metal
content discharged.
PIGMENTS IN TEXTILE PRINTING
In some cases, textile printing companies may use
metal containing pigments which may not appear in the
Color Index. Here also the copper is bound as an integral
part of the chromophore molecule.
Pigment Percentage & Content
Inmont Respad Green GB3W 0.80
Inmont Respad Blue G3W 1.40
Inmont Respad Blue GH3W 1.35
Inmont Respad Blue GL3W 0.10
Inmont Respad Violet V3W 1.15
Inmont Respad Grey R3W 0.10

Reason for Scouring

REASONS FOR SCOURING
REMOVE THE THICKENING AGENT
REMOVE AUXILIARIES
REMOVE EXCESS DYESTUFF
IMPROVE BRILLIANCE OF PRINT
IMPROVE FASTNESS PROPERTIES OF
PRINT
PROBLEMBACK
STAINING OF UNDYED AREAS

Auxiliary Chemicals

AUXILIARY CHEMICALS
THOSE NECESSARY FOR FIXATION OF DYE INTO FIBER
REACTIVES - ALKALI
VATS - REDUCING AGENT
ACIDS - ACID
CATIONIC - ACID
DISPERSE - CARRIER
Do NOT INCORPORATE STRONG ACID, BASES, OXIDIZING AND REDUCING
AGENTS IN PRINT PASTE.
ACID AGER
LATENT REDUCING AGENTS
(SODIUM SULFOXYLATE FORMALDEHYDE)

Dyestuffs Used in Printing

DYESTUFFS USED IN PRINTING
SAME AS THOSE USED IN DYEING
SPECIAL REQUIREMENTS
HIGH SOLUBILITY, DISPERSIBILITY
EXCELLENT WETFASTNESS
COTTON - REACTIVES, VATS, NAPHTHOLS
WOOL - ACID, METALIZED
NYLON - ACID, METALIZED
ACRYLIC - CATIONIC
ACETATE - DISPERSE, CATIONIC
TRIACETATE - DISPERSE
POLYESTER - DISPERSE
QIANA - ACID, DISPERSE

Step in Printing Process

STEPS IN PRINTING PROCESS
1. Preparation of Print Paste
2 Printing of Fabric
3. Drying
4. Fixation of Dyestuff
5. Washing - off

Main Problems in Printing

MAIN PROBLEMS IN PRINTING
COLOR - Dye and Paste Dumps; Clean-ups
METALS - Dye Dumps; Screen Making; Photo Developing
SUSPENDED SOLIDS - Print Paste and Clear Discards
SOLVENTS - Emulsion Thickeners and Clean-ups
HOT WATER - Afterwashing
BOD - Desizing; Print Paste and Clear Discards
FOAM (Floating Solids) - Carpet Printing

Waste Characteristics for Textile Printing

WASTE CHARACTERISTICS FOR TEXTILE PRINTING
Hard to Treat Wastes
Color from Dyes or Pigments
Toxic Organic Chemicals
Metals
Phosphates
Dispersible Wastes
Print Paste Components
Thickeners, Binders, Humectants, etc.
Hazardous or Toxic Wastes
Metals
Organic Solvents
High Volume Wastes
Scour and Afterwash Water
(Hot, Warm and Cold)

Textile Printing

Textile Printing- The application of color to a fabric in
a design or pattern (localized dyeing)
Modern printing generally incorporates one of the following
techniques:
1. Flat-bed Screen Printing
2. Rotary Screen Printing
3. Engraved Roller Printing
4. Heat Transfer Printing