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TEXTILE PRINTING

(FLAT SCREEN PRINTING)

Lecture# 35-38

Mujahid Mehdi Abro Indus University Karachi.


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Flat Screen Printing Machine

The New Magnoprint Flat Screen Printing Machine is


the most versatile and fastest flat screen printing
machine on the market, suitable for all kinds of textile
fabrics. The repeat length, the speed and the number of
squeegee strokes as well as the magnetic power are
individually adjustable on each printing station. Available
printing widths are 165 / 185 / 225 / 250 / 285 / 330 cms
with up to 24 printing stations.
Parts of Flat Bed Screen Machine
&
Function:

1. The pneumatically lifted unbatching arm


2. The Cloth Cleaning Device
3. The oscillating Cloth Pressure Roller
4. The touch screen operator panel
5. Magnetic Roll Rod
6. washing device
7. The dryer cabinets
8. The cloth exit device
The pneumatically lifted unbatching

The pneumatically lifted


unbatching arm comes with an
automatic digitally controlled
speed control drive system,
suitable for any kind of woven
and knits which are supplied to
the printing machine
The cloth cleaning device
The cloth cleaning device
assures to protect the printing
process from dust and fluff.
Depending on the quality of
cleanness of the textile goods we
offer a very effective suction
system, which optionally can even
be combined with a brushing,
blowing or beating system.
The oscillating Cloth Pressure Roller

The oscillating Cloth Pressure Roller


comes with a special silicon rubber
coating surface, assuring as such the
avoidance of cross marks on the textile
goods.
The touch screen operator panel
All top quality electronic components are
mounted into air-conditioned cabinets. The
CAN-BUS system connects all controls,
drives and sensors on the printing
machine. Printing design memory eases
the job for your repeat orders.
washing device
For a high speed quality printing
process, the printing blanket must be
cleaned fast, strong and carefully at the
same time. The stainless steel washing
device therefore comes with two single
driven full-surface brushes, high-quality
nozzles, pre-cleaning and pneumatic
drying squeegees and an automatic water
recycling system for a minimum of fresh
water consumption.
Magnetic Single Roll Rod
Magnetic Single Roll Rod Can
be chosen in various different
diameters from 6 to 50 mms.
Repeat adjustment may vary
from 60 to 600 cms. Each
magnet bar carriage is
equipped with an individual
servo drive with stepless speed
adjustment.
Twin Roll Rod System
Twin Roll Rod System usually
offers its advantages by deeper
penetration of the colour at a
faster production speed than
any other printing method.
Large diameter hollow roll rods
assure deep penetration and
perfect reproducibility with your
repeat orders.
The dryer cabinets
The dryer cabinets can preferably be
mounted on a substructure in a height of
1,0 up to 2,8 meters above ground floor
level, in order to gain space underneath
the dryer for the storage of accessories or
textile goods. The vertical fabric draw-off
optimizes the visual control for the
operator, especially for the printing of
flags, heavy materials, terry towels or
blankets.
The cloth exit device
The cloth exit device can be designed to
your individual needs. Optionally an
electronically controlled central winder, or
even a high quality surface winder with a
pneumatic batching arm can extend the
standard plaiter. Sensitive tension control,
antistatic-devices, J-Box or inspection
table for visual control of the printed textile
can be used as well.
WORKING PRINCIPLE OF FLAT SCREEN
Working
The main features of a typical automatic flat-
screen machine are illustrated in Figure.

All the screens for the design (one screen for each
color) are positioned accurately along the top of a
long endless belt, known as a blanket.

A machine intended to print traditional furnishing


designs might have space for 15 or more screens.
Contd
The fabric is gummed to the blanket at the entry end and
moves along with the blanket in an intermittent motion,
one screen-repeat distance at a time.

All the colors in the design are printed simultaneously


while the fabric is stationary; then the screens are lifted
and the fabric and blanket move on.

When the fabric approaches the turning point of the


blanket, it is pulled off and passes into a dryer.

The soiled blanket is washed and dried during its return


passage on the underside of the machine.
Fully automatic flat-screen printing machine
(simplified diagram); Rollers 1 and 2 move as
shown, to maintain the lower side of the blanket in
constant motion, 3 is the pressure roller, 4 the
temporary adhesive application unit and 5 the blanket
washer (Buser).
MAIN SYSTEMS
OF
FLAT SCREEN
Main Systems
Adhesive System:

This is to apply a water-based adhesive to the blanket at


the entry end, by means of a brush running in a trough
containing the adhesive solution, and to spread the layer
more evenly with a rubber squeegee; the fabric is then
pressed against the tacky blanket with a pressure roller. A
hot-air dryer is sometimes employed to dry the adhesive
before the fabric is printed.
Contd
Squeegee Systems:

When flat screens are used for printing, the paste can be
spread across the screen either along the length, or across
the width. One, two or more passes of the squeegee can
be made as required. The two most popular squeegee
systems are described below:

Double Blade Squeegee.


Magnetic Rod Squeegee.
Contd
Double Blade Squeegee:

This system is illustrated in Figure 2.7. A pair of parallel rubber-blade


squeegees is driven across the screen with the print paste in the gap
between them. Only the rear squeegee makes contact with the
screen, the leading squeegee being raised slightly above it. When the
next stroke is made, the leading squeegee for the first pass becomes
the rear one for the reverse direction.
Contd
Magnetic Rod Squeegee:

A completely different approach was adopted by Zimmer, who


invented a rolling-rod squeegee moved by an electromagnet, driven
intermittently under the blanket. This type of squeegee is used in
Zimmer flat- and rotary-screen printing machines,
Contd
Intermittent Movement:

The intermittent movement of the blanket should be more


perfect than any other thing, it will give the fabric design a
perfect look, and if it is not moving in an accurate manner,
then it will give problem to the print fabric, the fabric will
be not even in design.

Care during intermittent movement:


Accurate movement of the blanket

Discontinuity of gumming and washing

Control of fabric speed through the dryer


PRODUCTION
OF
FLAT SCREEN
DEPENDS UPON
Production Depends Upon
Number of Squeegee Passes:

Sometimes more than one pass is required to achieve


uniformity and adequate penetration, especially in mark
areas. This applies particularly to thick fabrics and those
with irregular surfaces.

In some machines the squeegees can be used to make a


stroke while the screens are in the raised position
(known as a flood stroke). This fills the mesh in the
printing areas of the screen with paste before the screen
touches the fabric, and more color is applied with the
first stroke when the screen is lowered.
Contd
Repeat Size:

Where the squeegee movement is widthwise, the


greater the lengthwise repeat the further the
blanket moves forward at each pass;
consequently the printing speed is greater. The
effect is less marked if the squeegee movement
is lengthwise, as the squeegee will take longer to
move along the screen where the repeat
distances are large.
Contd

Number of Colors in Design:

If the pattern has less no of colors in it, it will


give us higher production rate.

If the pattern is blotch, and contains more colors


it will reduces the production rate.
Contd

Efficiency of Dryer:

If the dryer is short, or if the temperature in the


dryer is too low, the printing speed will have to
be reduced in order to ensure that the printed
fabric is adequately dried.
FACTORS AFFECTING
FLAT SCREEN
PRINTING
Factors Affecting Screen Printing
The mesh (threads per inch) of the screen fabric; generally a coarse mesh allows
more paste to pass through than a fine one.

The hardness and cross-section of the squeegee blade; a hard rubber squeegee
with a sharp cross-section is suitable for outlines, whereas a soft, rounded blade
applies more paste.

The viscosity of the print paste; within the constraint of the requirement for good
definition, the viscosity can be varied, thinner pastes passing through the screen
pores more readily than viscous ones.

The number of squeegee strokes; from two to four strokes are usually applied.

The squeegee angle and pressure.

The speed of the squeegee stroke.

All these variables should be taken into consideration, in conjunction with the
nature of the design, when printing the chosen fabric.
AFTER TREATMENTS
After Treatments
After treatments are the main factor to give the
design a recommended look.

They varies with respect to the fabric nature and


printing nature.

If the treatments are not given properly to the


printed fabric with respect to the shade of design,
it will not give suitable result to the fabric.

It is done after the fixation of dye or pigment onto


the fabric.
Contd
After the fixation of print, the fabric is then
finished mechanically and chemically to get
the best feel for the fabric.

Followings are the finishes done on the


fabric:

Calendaring ( To get luster or shine)


Sanforising ( To minimize the shrinkage)
Softening ( To give the fabric a soft feel).
Faults
Following are the faults which comes in a fabric if it is
not treated well:

Fluff
Design out
Crease
Miss print
Bubble
Color spot
Splashing
Registration
Frame mark
Advantages & Limitations
Advantages:
Cost Effective.
14 to 16 colors can be used in a
single design.
Blotch designs can be made easily.
Big repeat designs can be made.
Areas of far greater size can be
stenciled. Frames 1.27m X1.52m
(50 X 60) are frequently used for
Contd
Limitations:

Big space consumption.


It is unsuitable for very long runs.
It is a relatively slow printing
process.
Manufacturers

Buser (Switzerland)

Stork (Netherlands)

Zimmer (Austria)

Reggiani (Italy)

Benninger (Switzerland)

Ichinose (Japan)
Applications

Blanket Printing

Home Textiles Fashion

Towel Printing Flag

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