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All-over printing vs all-over digital printing (Part-2)

In the first part, I discussed on ‘difference between ‘all-over printing’ and ‘all-over digital printing’; Companies with AOP printing facility in Bangladesh; continuous process flow chart for all-over digital printing; advantages and disadvantages of digital printing, etc.

all-over-digital-printing-machine-Bangladesh
Figure 1: Bangladesh printing sector uses the best available all-over digital printing machines.

In the second (last) part, I will depict the history of all-over digital printing in Bangladesh, popular all-over digital printing machines that are using by Bangladesh textile industry; Major problems and solutions of digital printing, etc.

All-over digital printing in Bangladesh

All-over printing (AOP) project started its journey in the 1980s in an export oriental factory of Bangladesh, and 2020, all-over the printing project has been running about in 80 factories. Today, Bangladesh has gained the skill to compete with any country in the world with AOP and has created a strong position. But we are still far behind in all-over digital printing.

Also Read: All-Over Printing vs All Over Digital Printing (Part-1)

Lacking efficient manpower, poor application technology, low-quality raw material and poor fabric quality are the main reasons for this situation. Also, we do not have any learning opportunities for digital printing technology. That is why fresher graduates and experienced technologist cannot enrich their knowledge about digital printing technology. Our competitors like China, Pakistan, and Turkey, etc. are growing very fast in this industry.

For the first time in 2014, Beximco started all-over digital printing in the Bangladesh textile industry. Now 20 factories in Bangladesh use all-over digital printing having different brands, different facilities, and different production capacities. In our country, most of the factories are using the machines of below six brands –

top-all-over-digital-printing-companies
Figure 2: Most of the Bangladeshi printing factories are using the all-over digital printing machines of six brands.

Reggiani Machine (Italy brand) is the best. Reggiani Machine’s print quality is good, production speed is fast, and the operating system is easy as well. We need diversification in the textile industry if we want to survive shortly. So, the investors need to focus on digital technology as soon as possible.

Here is a list of the factories in Bangladesh that have Digital All-over Printing Machines:

Dird Composite Textile Ltd

Durst Alpha 190 Machine (Italy Brand)

Reactive Print.04

Head: 64

Head name: Kyocera

Max.width:1900 mm

Production capacity: 5000 m/day.

Knit production capacity: 1200-1300 kg

NAZ Bangladesh Ltd

Zimmer Machine.

Reactive Print.

Head :32

Head name: Fuji Diamatix

Max width:1800 mm

Starfire-sa-1024

Production capacity:3000 yds/day

Silver Line Composite Textile Ltd.

Zimmer

Reactive Print.

Head:64

Max width:1800 mm

Head name: Fuji Diamatix starfire-sa-1024

Production capacity:6000 yds/day

Hossain Dyeing & Printing Limited.

Homer digital print.

Reactive print

Head name: Kyocera

Head: – 16

Max width:60 inches

Production capacity:2400 yds/day

Nice Fabrics Processing Limited.

Attexco Machine (China)

Reactive Print.

Head: 32

Machine(small)

Max width: 35-72 inch

Machine (Big)

Max width: 35-100 inch

Print Capacity: 300 mtr per hour.

ACS Textiles (Bangladesh) Limited.

MS Machine (Italy Brand)

Reactive Print.

Head:32

Max width:124 inch.

Production capacity: 5000 yds/day

 

Jamuna Group.

Reggiani Machine. (Italy Brand)

Reactive Print.

Head-16

Max width: -70 Inch

Production capacity: 3500-4000 yds/day

Pran RFL Chorka Textile

Atexco Machine

Reactive Print.

Head-16

Day-64-inch max

Production capacity: 2200 yds/day

Beximco Textile Division.

Machine name: Reggiani (Brand Italy)

Print type: – Reactive print

Head-16

Head name: – Kyocera

Color: 8 color Printable

Max width: 72 inches

Production Capacity: Woven-3000 yds/day. Knit – 500-800 kg/day

 Mondol Group.

Durst alpha 190 Machine (Italy Brand)

Reactive: Print.

Head: 64

Max width: 74 inches

Color. 8 Knit

Production capacity knit:1000 kg/day

Woven: 5000 yds/day

GMS Composite Knitting Industry Limited.

Machine 1: Durst Alpha-330 (Italy Brand)

Reactive Print.

Head: 64 Ricoh Gen 5 Print Head Ink quality: – HD

Max width: 130″/3.3 metre (working area).

Color: 8 (Cyan, Magenta, Yellow. Black, Red, Orange, Blue, Grey)

Production capacity: Knit:1200 kgs/day & Woven: 4500/ 5000 yds/day

Machine 2: 2 Durst Alpha_190_Italy Brand

Print type: Reactive Print.

Head: 64 Ricoh Gen 5 Print Head Ink quality: – HDI

Max width: 74″/1.9 meter. Color: 8 (Cyan, Magenta, Yellow, Black, Red, Orange, Blue, Grey)

Production capacity: Knit:1200 kgs/day & Woven: 4500/5000 yds/day

Robintex Group.

Machine 1: Durst Alpha 190 Brand: Italy

Print type: Reactive print

Head-32, Richo Gen 5)

Color: 8 color

Printable width: 72″

Capacity: woven-3000 yds/day Knit – 600-800 kg/day

Machine 2: MS LARIO Brand: Italy

Head: -164 Approx.- Kyocera)

Print type: Reactive print

Printable width: 72″

Capacity:15-20 ton /day

Machine 3: MS JPK EVO For Disperse Brand: Italy

Head: -32 Print type:

Reactive print Color

8 color Printable

width: 72″

Capacity: woven-5000yds/day Knit – 1500 kg/day

Machine 4: MS JPK EVO for Pigment Brand: Italy

Print type: Reactive print

Head: -32

8 color

Printable width: 72″

Production Capacity:1500 kg/day

Echotex Textile Ltd.

Reggiani Machine. (Italy Brand)

Reactive Print.

Head: 32

Maximum print width- 72-74 inches

Production capacity: 5000 yds/day

Apex Holding Limited.

Reggiani machine. (Italy brand)

Reactive print.

Head:16

Max width:64 inches

Knit Concern Group

1. Reggiani Top and Reggiani Renoir.

Made in Italy

Reaktive Ink

Head: -32

Color -8

Printable width: 72- 97 inches

Capacity -1500 kg /day, 1 mc, knit fabric. 6000 meters Woven 1 mc

Machine 3: Sublimation

Reggiani Compect.

Made in Italy

Head:16

Color: 8 Dispas ink

Capacity: 4000-5000 meter

Sulimation paper print

Experience Textile Ltd.

Atexco Machine

Reactive Print.

 

HR Textile Mills Limited.

MS JP7 Machine (Italy Brand)

Head: 16

Head name: Quicera

Production capasity:500 m/day.

Only woven fabric print machine.

Utah Group

Reggiani Machine. (Italy Brand)

ReactivePrint.

Head: 32

Maximum print width- 72-74 inches

Production capacity: 5000 yds/day (Approx)

 

Viyellatex

Durst alpha 190 Machine (Italy Brand)

Pigment Print.

Head: 64

Max width:74 inches

Colour. 8 Knit

Production capacity knit:1000 kg/day

Woven: 5000 yds/day (Approx).

Unicom

Texlink machine (China)

Head: 16(Kyocera)

Print type: Reactive Print

Color:  8 Color

All-over-printing-All-over-Digital-printing

Impact of coating chemical in digital printing

Standard recipe for reactive

Thickener (PC-130)-3%

Urea- (8-10) %

Sodium bicarbonate- 2%

Resist salt-1%

Rest amount of water

Parameters

Temperature- Not more than 120°C.

Speed- About 20m/min. It can be changed according to the thickness of fabric.

Pressure-(3-5)

Packed the coated fabric with poly as soon as possible otherwise, urea can absorb water from the environment which can destroy the printing effect.

Advantages

  1. High color yield
  2. Better permeability
  3. Good definition
  4. Better hand feel
  5. Easy to wash and have excellent fastness to rubbing.
  6. High quality and save ink- save money
  7. Stable printing

From the above discussion, it is clear that the selection of coating chemicals is very important for digital printing. PC-130 is one of the reactive digital printing pastes of Zhongshanshi Ideal New Materials Company Ltd, Guangdong Province, China. This company provides the full solutions to digital printing auxiliaries for all kinds of fabric.

Major problems and solution of digital printing

1. Color staining problem In case of dark color print, the problem happened in the unprinted area.

This problem can be solved by following ways-

a) Fabric shouldn`t come into close contact with each other during loop formation in steaming.

b) Selection suitable coating recipe.

c) Wash should be perfect so that no excess color in the fabric.

2.Centre to side running shade problem For full coverage design this problem normally happens. This can be minimized by-

(a) Wash the fabric properly before coating.

(b) Check all fabric parameters (i.e. absorbency, fabric PH, oil etc.) before coating.

3. White spot This problem can be solved by following way-

a) Remove the protruding fibers from fabric surface before coating by singeing or enzyme.

b) Clean the chemical tank properly before coating.

4. Low color yield It`s a very common problem in textile industry of Bangladesh. The situation can be improved by following way:

a) Singeing and mercerization for both knit and woven fabric

b) Selection of suitable coating chemical. For digital printing, coating chemical has a big impact for color yield.

5. Shade variation problems: Most critical problem we face in digital printing is shade variation. We print same design but after finishing we get different shade. This can be minimized by-

(a) Coating chemical needs to make properly. Check the viscosity and PH.

(b) During streaming, washing and finishing need to keep all parameters same.

I am really grateful to them who have helped me in different ways and given me different information to write this article. I would like to specially thanks:

Md Anwar Hossain, Technical Service Manager, Zhongshanshi Ideal New Materials Company Ltd, Guangdong province, China, Cell: +8801722235791 or +8618302079088 E-mail: anwar@zs-ideal.com

Md Nasimuzzaman (Nasim) Jr. Asst. Vice President, RobinTex (Bangladesh) Limited

Nuzhat Zerin Islam, Student of Textile Depertment, Ahasanullah University of Science and Technology (AUST)

Kawsar Azam Anik, Electrical and Electronic Engineering (EEE) at Khulna University of Engineering & Technology

Kamal Pasha, Designer at Knit Concern Group and

Mamun Hossain Shagor, Fashion Designer at DBL Group

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