Methods of printing:

1. Block printing---(i)By hand (ii) By machine

2. Stencil printing
(i) Metal stencil
(ii) Screen stencil
3. Roller printing
4. Screen printing
(i) Hand screen
(ii) Semi-Automatic flat screen printing
(iii) Fully Automatic flat screen printing
(iv) Rotary screen printing

5. Transfer printing
(i) Flat-bed press transfer printing m/c
(ii) Continuous transfer printing m/c
(iii) Vacuum transfer printing m/c

1. Block Printing: Block printing is the oldest method of printing which still exists but use
is limited to the decoration of scraves and handkerchiefs.
Block size: Generally 3” X 4”—4”-12”
Maximum—36” X 36”
Required equipment:
I). long table (generally made of wood).
II). sieves.
III). Resilence pad of woolen felt cloth/foam.
IV). Gummy cloth.
V). Back grey.
Table size: Length—as required.
Width—1.5-2 m
Height—depend on labour height.
Block preparation: Generally block is made from pear wood which is cut so that the
design is raised in relief. The size of the block depends on the design characteristics. Normally
block is used only for single colour. The printing does not become uniform with large size block.

Printing procedure:
 The fabric for printing is stretched on a flat table covered with resilience substance
and then back grey and gummy cloth.
  The printing paste is kept in a colour pad which is a blanket. The colour pad or
sieves is kept in a colour tray.
 The block is pressed into the sieve and smeared with colour paste. Then it is raised
and pressed upon the fabric so that coloured pattern to transfer to it.
Advantage:
 The method is simple to operate and does not require elaborate and expensive
equipment.
 Design in any no of colours and on any scale can be reproduced.
 Fast rate block print possess richness, fullness and purity of colour.
 There is no limiting factor in repeat unit.

Disadvantage:
 Slow method, low output and hence costly.
 Not possible to obtain sharp out lines of design.
 Difficult to join up each impression or repeat perfectly.
 This method involves manual work and hence quite laborious.

Stencil Printing:
-Stencil made from (I) Steel (II) paper (III) plastic (IV) Laminated.
Paper: Transparent paper imaging a design and then chemically treatment to make water
proof.

Kinds of stencil printing:

I). by brushing.
II). by spray.

Procedure: Direct style of printing is applied in this method by two ways- spraying or
brushing. The stencil is placed on the fabric and colour is applied by means of brushing
or spraying.
It is used decorate knitted fabric.

Advantage:
 Stencil is much easier handle than the block and the cost of production is low.
 Possible to produce various shade effect.
 Direct application of print paste and any kind of colour can be used in stencil.
IV).Profitable for small scale production.
Disadvantage:
 Complete circular/rings can’t be obtained and designers freedom is limited.
 Complex design is not suitable.
  Not suitable for large scale production.
 It involves manual work and hence laborious.

Roller printing:
Roller printing or M/C printing is the most economical and fastest way of printing. The
output of this M/C can not be surpassed by any other method of printing. Designs with up
to 16 colours present no problem in Roller printing.

Construction:
 This M/C consists of a central pressure bowl(1) suitably wrapped with layers of
cloth called lapping (2) around which an endless woollen blanket (3) ,a back grey (4)
and the cloth (5) to be printed circulate in contact with each other.
 An engraved printing roller of shell (6) mounted on a steel shaft or mandrel (7)
revolves in contact with the pressure bowl above and a furnisher roller (8) below
which partly dips in the printing paste kept in the colour box (9).
 A sharp edged steel blade called colour doctor (10) rests on the engraved roller on
one side and a brass blade lint doctor(11) rests on the other by suitable weights
and levers.

Working procedure:
 The fabric to be printed is placed on the impression cylinder. The pressure cylinder
comes to the contact of engraved roller by rotating forwards.
 The engraved roller is first supplied with the printing paste by the furnishing
roller. This paste is deposited in the engravings as well as applied on the smooth
surface.

Fig: Roller printing m/c

 When the engraved roller rotates, it comes into contact with the colour doctor
which scrapes the excess colour (paste) from the smooth surface and allows the
paste deposited in the engravings to remain there. Subsequently, it makes an
impression on the fabric by depositing the paste contained in the engraving.
  During the further rotation of the engraved roller, it meets the lint doctor which
is placed at an angle against the rotation of the roller. It cleans the engraving rollers
by removing fibrcs, faulty mtls.
 A no of engraved rollers provided with separate furnishers, colour boxes and colour
doctor and lint doctors are lplaced around the central pressure bowl so that by a
single passage of the cloth through the M/C all the colours required in the design
are printed, each roller supplying a part of the design.

Advantages:
 Suitable for large scale production.
 High speed M/C and hence more production.
 Can be used for fine printing.
 Can be made/prepared high quality design due to not joint mark.
 Possible to print in complex weaven design.

Disadantages:
 Changing time high. So not suitable in small scale production.
 Engraving the printing roller is an expensive operation.
 May be light printing shade.
 Crush effect produce.

Screen Priting:
1. Hand Screen printing.
2. Flat bed screen printing.
 Semi-automatic
 Full automatic
3. Rotary screen printing.

Fundamental characteristics of Screen Printing:

(1) In screen printing process, hydrodynamic pressure is built up in the print paste
between. the squeeze and the screen surface through which the paste is passed. Important
elements here are the force (pressure) exerted by the squeezes, the holes through which
the paste must pass .
(2) The % of open area of the screen also plays a role. More open screens allows
more paste to pass.
(3)The fabric to be printed forms a three dimensional structural with the screen
where the absorbency of the fibers and penetration capacity between pores also affect the
take up of the paste.
 (4)The usual hexagonal opening which are larger at the outside of the screen that’s
at the inside the capillary and surface tension forces etc result in a printing with actually
more colour deposited in the areas between hole than opposite holes.
Pore Printing paste

Factors to be considered for good screen printing:

The amount of paste which is pushed through depends upon-
1. The fineness of the screen.
2. The hardness of the table.
3. The viscosity of the printing paste.
4. The no. of the squeeze strokes.
5. The speed of the squeeze strokes.
6. The hardness and X-section of the squeeze blade.

Hand Screen Printing: Printing table is arranged in the shade vertically. The fabric to be
printed is placed on the table in tension and welded with gum. Then screen is placed on
table and printing paste is given on it. Paste is attached through screen according to
design by moving squeeze 2 or 3 times. As a result engraved design on screen is printed
on fabric. Then dried by heat arrangement below table.
Screen

Fabric

Back grey

Table

Fully Automatic Flat Bed Screen Printing:

Feature:
 The M/C consists of a printing table (flat bed) an endless conveyor belt to bring
the fabric onto the table under screen.
 A no of screens a special mechanism for lowering the screen on the required parts
of fabric.
 Squeezes are driven by motor.
 An arrangement for gumming the fabric on conveyor belt by a driver.
  Special arrangement under table to collect extra paste.
 Speed 5-20 m/min.

Squeeze system:
1. Double blade squeeze.
2. Magnetic Rod Squeeze.

Fig: Automatic Flat bed screen printing m/c

M=Fabric to be printed,
S1,S2, S3, S4 =Screen
t=Printing table, d= Conveyor belt
W=Washing device for blanket
I=Device for bringing gum to the printing table.

Procedure:
 The fabric to be printed is feed to the printing table by feed system and is welded
by glue with endless conveyor belt.
 The conveyor draws forward below screen in equal difference and printing paste
mechanically supplied is welded on fabric according to design by squeeze through
screen.
 Automatic squeeze system of individual screen is controlled by mechanically or
electro magnatic power with individual motor.
 By using different colours in different screens, printing effect of different colour
can be made.
 By washing device weld glue on belt can be cleared.

Advantage of Automatic Flat Bed Screen Printing:

 The flat bed screen printing method is mostly used for sarees.
 Easy and very cheap to prepare screen.
 The colours have a transperancy, purity and richness.
 Upto 14-16 colour in one pattern can be produced.
 Since the whole width of fabric is printed at a time, its faster than block printing.
  Comparatively cheap than roller printing.
 Wastage of printing paste is less.

Disadvantage of screen printing:

 Joint markers at the repeat often precipitated.
 For high production a large no of tables have to bel used requiring huge space.
 Fine mesh screen used for sharp designs are often chocked.
 Production is less than roller printing.

Rotary Screen Printing:

Feature:
 A perforated cylinder or spherical screen.
 Each screen is independently driven.
 Printing paste is fed to individual screen by special pump.
 The printing paste level inside the rotory screen is automatically and constantly
controlled.
 The transfer of printing paste through the perforations of the screen into the fabric
is governed by specially designed squeeze blades.
 Gummy device.
 Washing device.
Procedure:

Fig: Rotary screen printing m/c

M=Fabric to be printed, d=conveyor belt
W= Washing device, L=Device for bringng gum to the blanket.
 At the time of printing, the fabric is brought on and placed on the conveyer belt
through feeding system.
 The conveyer brings the fabric continuously under the series of rotary perforated
screen made of metal foil where the printing colour is passed through the squeeze
inside each rotary screen forces the printing paste into the fabric.
 The conveyer belt is cleared with water once during each revolution by the
washing device.
  In this method, print paste is fed to the different screen individually by special
pumps.

Advantages:
 Highest production.
 As many as 24 colours in a pattern can be produced, 8-10 colour can be printed
easily.
 No joint mark.
 Suitable for woven and knitted fabric.
 Stripe design can be done in warp.
Disadvantages:
 Printing cost is high due to high price of screen.
 Not suitable for short runs.
 Different screens are needed for varying colours.
 Not possible of fine line design.

Difference between. Rotary Screen and Roller Printing:

Rotary Screen Printing Roller Printing
1. Printing is done by specially 1. Printing is done by specially
made perforated cylindrical or engraved cupper roller.
spherical screen
2. Paste is pumped to the screen and 2. Paste is transferred to the engraved roller
distributed lengthwise by pumps. by colour furnishing roller.
3. Upto 24 colours can be printed but 8-10 3.Even 16 engraved roller can be used for
are printed easily. different colours of
pattern only 4-6 may
4. Can be printed woven and knitted fabric. 4. Can be printed woven and tricot fabric.
5. The main equipment of printing is rotary 5. The main equipment of printing is
screen Engraved roller
6. Design can be changed quickly 6.More time required for changing of pattern.

7. Engraving costs slightly lower than copper 7. Engraving costs is higher.

roller.
8. Setting up time- lower 8. Setting up time -higher
9. Production rate-high 9. Production rate medium
10. Pressure of fabric-low 10. Pressure of fabric-high
11. Skillness required by the operator is low 11. Skillness required by the operator is high
12. Colour applied is more adaptable. 12. Colour applied is less in general.

Transfer Printing: Transfer printing is such the printing which can be printed on fabric
by transfering design of printing paper using only methods.
 Printing ink
Transfer
Printing paper
Transfer
Textile mtls.
Basic Principle:
Transfer printing technology is done by two steps-
 At first step, the definite design is printed on transfer paper by sablimable dyestuff
paste. This transfer paper is printed by flexographic lithographic.
 In 2nd step- this transfer paper is kept contact into the fabric to be printed. As a
result design of printing paste is transferred to the fabric from transfer paper under
the condition of time, temp and pressure.
In this method cut piece fabric is printed in flat bed M/C and long fabric is printed by
continuous transfer printing M/C.

Types of transfer printing M/C:

1. Flat bed process transfer printing M/C.
2. Continuous transfer printing M/C.
3. Vacuum transfer printing M/C.

Advantages of Transfer Printing:

 Standard printing can be done by this printing.
 No washing off or No need of after treatment.
 It is possible to guarantee delivery of small and large quantities in a short time.
 Produced fabric is not stiff.
 The degree of wastage is very small.
 Suitable in knitted fabric.
 The cost of the equipment is low.

Disadvantages:
 Only volatile dye can be used.
 The technique mainly aims at synthetic fibres baised on synthetic polymer.
 There is extra step of 1st working on paper.
 Once the transfer printing paper has been used it cannot be used.
 Costly.

Defects in Roller Printing:

1. When grit particles in the printing paste cut the smooth surface of the unengraved
roller, the scratches produced will also transfer the paste to the cloth.
 By burnishing the roller as well as by straining/filtering the printing paste again
this fault may be removed.
2. Sometimes large double stripes of colour called snappers appear along the length
of the cloth due to solid coming under the colour doctor edge.
Washing, cleaning the doctor blade, roller and filtering the paste are to prevent this
defects.
3. Very minute snappers called litts are produced at regular intervals on the cloth
because of particles of steel getting embeded in the engraving of the roller. Cleaning
the roller engraving can prevent this fault.
4. Streakes appear as fine lines or series of lines running along the piece and parallel
to selvedge due to scratches on the engraved roller and cut in the colour doctor
blade edge. Polishing the roller and sharpening the doctor blade edge can remedy
this problem.
5. Scumming is the fault arising out of insufficient scraping of the printing paste from
the unengraved portion of the printing roller by the doctor blade.
6. Uneven printing is another fault due to the faulty of the cloth, the roller, the
printing paste and working of the M/C.
7. The printed cloth with deeper shades near one selvedge than near the other due
to uneven pressure exerted by the engraved roller on the pressure bowl and faulty
setting.
8. If the fitting of the engraved roller on the mandrel is not perfect, it slips while
rotating, this defect known as lobbing of the engraved roller.

Screen printing faults:

1. When uneven pressure is exerted by the squeegee during the stroke, the resulting print
becomes lighter on one selvedge and becomes gradually deeper towards the other
.Uneven steaming may also lead to this fault.
2. The prints may come out lighter in the middle and deeper towards the selvedges. This
occurs when too much cloth is steamed in one batch or when the cloth is very thick.
3. Very small specks of colour appear on the ground (unprinted portions) when the screen
has tiny holes in the blocked areas. In this case, the screen should be inspected and lacquer
applied at these places.
4. When the printing has too much solids in it, especially in pigment printing, the screen
may got choked (clogged) during working. This results in light prints after working for
some time.
5. When the screen is placed on a previously printed area with another colour, which is not
dried , the back of the screen picks up some paste and transfers it to the next area where
it is placed, leading to smudging of the print.
6. Deeper prints are obtained irregularly throughout the material. This may due to uneven
table surface and hence the squeegee exerts different pressures at different places.
7. If the squeegee vibrates while applying the pressure (stroking) deep stripes along the
warp appear.
 8. When a paste containing a large amount of foam is printed, lighter prints are obtained
throughout the cloth.
9. Lighter prints occurring irregularly may be due to uneven application of eh gum while
fixing cloth on the table.
10. If a soft table is used on a hard table surface deeper prints are produced. On the other
hand, if a hard squeegee is used on a soft table surface, fine lines of the designs are not
obtained.

Difference between stencil and screen:

Stencil Screen
1. Oldest method 1. Moderation of stencil
2. For drawing of cicular line, need 2. Very easily
of combination bridge.
3. Less production. 3. More production.
4. It can proceeds with stencil 4. It can process by screen
5. Colour is applied on the
fabric by brush or spray 5. by moving the screen