Direct Method of Printing

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Direct Methods Of Printing Block And Roller

Compiled By :Amar KumarAmar Nath PrasadMd. Jawed Akhtar

National Institute Of Fashion Technology, Hydrerabad


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Direct Printing

Printing, in which colorants containing dyes,

thickeners, and the mordents or substances

necessary for fixing the color on the cloth are

printed in the desired pattern by the direct

application on the textile


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Direct Printing MethodsBlock Printing Block printing is a technique for printing text, images or

patterns using carved blocks

Roller Printing

Roller printing is similar to block printing except that thepattern is engraved on a cylinder to allow for a more efficientmeans of printing large quantities of fabric

Jet Printing

Jet printing is a non-contact application system originallydeveloped for printing carpets, but now increasingly used inthe textile sector

Digital Printing

Digital textile printing is a process of printing on textiles andgarments using specialized or modified inkjet technology


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Block PrintingA technique for printing text, images or patterns used widely

throughout East Asia and believed to have originated in China towards early

3rd century

The process is painstaking and demanding and the results are startlingly

beautiful. This method, though laborious is actually quite simple and merely

calls for precision

Apart from wood, blocks were made of metals and porcelain also. But

wooden block remains the most sought after apart from metal ones which has

gained popularity in recent times


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Steps involved in Block Printing

1. Carving of Blocks

2. Color Paste Preparation

3. Preparing the table and fabric

4. Printing


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1. Carving of BlocksBefore the printing can begin, woodcrafters have to carve the woodenblocks

The designs are intricate and theprinters need a different block foreach color in the design

Requires high precision in makingthe blocks for any multi-colordesign


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Cont

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When the carving is finished, thecarvers soak the blocks in oil to softenthe wood and prepare it to absorb thedyes


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2. Color Paste PreparationDyes or pigments

Thickeners

Binders, cross-linking

agents

Sequestrants

Dispersing agents surfactants

Water-retaining agents (humectants)

Adhesion promoters

Defoamers

Catalysts

Hand modifiers

Ingredients Used:


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3.Preparation of Table And Fabric

When the intricate work of preparing the wooden blocks is complete,the printers start on the table and fabric

The printers first pad a long rectangular table with wool felt to cushionthe printing process. To protect it from dye passed through the fabric,it is covered by a waterproof rubber Neoprene sheeting.

Then the printers pin the fabric to be printed onto padding. Cotton isthe most common type of fabric for block printing, although silk issometimes used.

Now the printers are ready to use one of three printing methods

direct, discharge and resist methods to print the fabric


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4. Printing

Of the three methods of block printing, the moststraightforward is the direct method

A printer first dyes the entire cloth a single color thatbecomes the background color of the design

Then the printers apply the dye from the wood blocks

on top of the background color

One printer will work along the length of the fabric printing thefabric with one color. Then another printer will come along behindher, using a different block to print the fabric with another color


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Cont..

A printer dips the wood block

into the dye then applies the block

to the fabric, holding the block by a

handle on its back. The printer uses

the points carved into the wooden

blocks as guidelines for placement.

Once the block is in place, the

printer slams the top of it hard with

her fist or mallet to make a clear

impression on the fabric with the

dye.


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Block Printing Advantage Disadvantage

Multiple colour designs are labour

intensive and require a lot of skillto register the prints exactly.

Colour variation is hard to avoid

with this method as print ink can

vary in quality of depth or colour.

Low production rate up to 100

Yard per hour

Availability of large repeat sizes

up to 183 cm/ 72 inches

Available in custom color and

backgrounds


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Roller Printing

Roller printing is

similar to block

printing except that the

pattern is engraved on

a cylinder to allow for

a more efficient means

of printing largequantities of fabric

The cylinder picks up

dye and selectively

transfers it onto the

fabric. Like with blockprints, different

cylinders are used for

each color applied in

the pattern


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Working Method

An engraved printing roller iscovered with the dye paste byfurnishing roller from the firstcolor box and the fabric is guided

between it and a central cylinder

While the printing roller is

revolving, extra dye is removed bya color doctor blade. It is done, inorder to keep certain andappropriate amount of color in theprinting roller. While the printingroller revolves it applies dye paste

in the surface of the fabric.


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Cont...

A lint doctor is present there to prevent the dye fromthe roller surface to be mixed up with the printed fabric

Continuously, the printing roller once again is coveredby the furnishing roller and prints the fabrics insuccession.

Different color box, furnishing roller, doctor bladeremain well arranged in a large pressure bowl so thatthe fabric can printed out as much dye as it needs.


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Cont

For effectively drive the roller printingmachine, there are some mechanicaladjustment method by which the extent of

printing can be controlled.

At the end of each batch the pastereservoirs are manually emptied into

appropriate printing paste batch containersand squeezed out. The belt and theprinting gear (roller brushes or doctorblades, squeegees and ladles) are cleanedup with water.


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Roller PrintingAdvantage Disadvantage

6 to 8 types of color to drawflower, design, reflection and

different thing on the fabricsurface can be used

High Production Rate andhence cheaper

roller printing machine even

use to create complex wovendesign or printing

Very fine details of design canbe achieved

Copper cylinders very

expensive

Not economical for short runs

Requires highly skilled

workers

Engraving the printing roller is

very expensive

Changing time is high

Higher coloring effect is not

possible as like block printing


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Direct Method of Printing

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