Now is the Best Time to Get into the Textile Printing Industry
https://www.sublimationinks.com/textile-printing-industry/
(This is a reprint of a good blog by Sabur Digital Technologies a UK Company link is above- Photographs are ours)
In this article we take a look at the history of textile printing, and the influence its had on the development of today’s printing technology and machines.
Around for thousands of years…
The earliest example of printing onto textiles dates back to the 4th Century B.C. The simple yet effective wood block printing method (which most likely originated in China) was used throughout East Asia and long before the technique was ever used to print on parchment or paper.
Spanish Conquistadors also discovered both the Incas of Peru and Chile along with the Aztecs of Mexico practised woodblock printing, but unfortunately there’s no documented evidence to confirm whether these ancient people discovered the art form for themselves or somehow imported the technique from East Asia.
Then in the 12th Century, and as a result of expanding trade routes, printed fabrics arrived in Europe. Produced in a hurry, the inferior dyes made for the European market tended to melt away when washed, therefore as decorative items didn’t need to be laundered, the technique was used to produce interior furnishings such as wall hangings and lantern covers.
UK Reach
In the early 1600s, the infamous East India Company began importing prints into the United Kingdom. Made from a plain cotton fabric and using only a single printed colour, the designs were specifically created for the reserved British tastes of the time. English designers also began sending floral patterns back to India, and as a result the market in printed textiles rapidly expanded, so mush so, UK based dye-houses began to open and printing techniques began to evolve.
Engraved copperplate printing
Prior to the introduction of these printing machines in 1783, engraved copperplates were used to press inked patterns onto the cloth. Of course even though this was a much quicker process than traditional wood block printing, due to the size of the copperplates, it was very difficult to match the pattern up. So as the result, the process was confined to textiles with a small print area, such as handkerchiefs.
The invention of textile printing machines
Patented by Thomas Bell in 1783, and first used in the Lancashire fabric mills, roller or machine printing began to produce printed cotton fabrics in the early 1790s.
Using a revolving engraved metal cylinder, the machine which could print one consistent colour onto the fabric, was not only capable of mass production compared to traditional wood block printing but was also very cost effective compared to traditional techniques.
Then by 1860 and following a number of key enhancements, roller printing machines could not only process expensive fabrics with delicate designs, but could also print up to eight colours simultaneously. However even with these developments in textile print technology, specialist woodblock printing, unlike traditional screen print which still exists today, was still needed to finish large scale soft furnishings, and wasn’t completely replaced by the commercial printing industry until the early stages of the 20th Century.
The introduction of digital machines
In the late 1980s, the industry made another leap in technology with the introduction of digital printing. Like its predecessor, the roller machine, this new type of machine began to revolutionise the industry. Using an ink-jet method to physically print colour dyes onto textiles, the process was originally used to produce very small orders such as corporate wear and fabric communication items such as flags and marketing banners. Then in the early 1990s came the development of the sublimation printer.
How does sublimation printing work?
Using heat sensitive inks, sublimation textile printing is a technique which uses high temperatures to turn the appropriate inks into a gas and then combine them with the structure of the fabric to replicate the image. Only for use on polyester, the design won’t crack or fade even when the printed item has been laundered a number of times.
How print design has evolved?
Unlike screen printing, digital provides the user with a lot more control in respect of the colours and inks used. However on the flip side, traditional screen printing can produce many more items at a time, making screen printing a viable option for substantial orders. This maybe due to the printing machine and the necessary ink cartridges required, not yet being large enough to process a substantial order. However with continued developments in technology, this shouldn’t be the case for much longer.
The main digital printing methods reduce the amount of time spent on set-up and production. Often used for artwork with a lot of detail, digital direct to garment printing also produces more colours at a higher resolution, without the customer having to compromise on the look of the design, or needing a traditional screen to be made for each colour.
The future of digital technology
Throughout the last decade, it has continued to rise in popularity. Easy to set-up especially for one off orders, digital printing has not only transformed the market, but created a number of additional revenue streams for print organisations. Furthermore, marketers are now able to commission branded products to amplify their campaigns, conferences or seminars, without having to place a large and costly order, or consider the amount of time required to produce their requirements. Plus driven by seasonal trends, retailers can now easily source point of sale signage and promotional materials.
With the ability to facilitate large requests, traditional screen printing still has a place within the industry. However when it comes to bespoke, small batch orders, digital textile printing is leading the way. From corporate branded tshirts, local sports team clothing, fabric goodie bags and even personalised home furnishings such as wall hangings, curtains, cushions, table cloths and duvet covers, the ease and cost effective production method has enabled printers to work with their customers to create bright and refreshing designs at a very cost effective price.
(Re-publishing of this article is not an endorsement of the originating company nor does it constitute their endorsement of MUTOH. Re-Published for educational purposes only.)
Read MoreGood Signage Means Communicating a Message
Sometimes being explicit is not the same as communicating. When you create signage that’s important, be sure to communicate the message!
Read MoreWhy So Tense? Head Strike Prevention on a Wide Format Printer
Could a Head Strike Really Be Related to Proper Media Tension?
When the words “head strike” come to mind, probably the last thing anyone would think of is media tension but the reality is that it could very well be the cause of those head strikes. Throughout my years in the service department with Mutoh America Inc. www.mutoh.com I have encountered media tension problems time and time again with some of our customers who weren’t even aware that our printers have different media tension settings. Media tension can cause all kinds of unwanted occurrences when you are trying to get your jobs out the door so knowing your specific printer’s tension settings can play a huge part in getting successful and accurate prints out to your customers as well as cut back on that unwanted lost/waste material.
Each roll to roll ValueJet has some sort of media tension adjustment on them but not all of them are adjustable so it is important to reference your user manual for your specific machine so that you understand the different tension settings and how to engage or disengage them. Take the 1638X for example, this model is adjustable and there are 3 different tension settings that you can set on the machine. The first one is no tension at all. With the tension, bracket disengaged the roll will spin freely and have no resistance.
The second and third are with the tension bracket engaged. You can add 1kg or 4kg of tension to your material by setting your damper knob accordingly.
With all of these different settings available you can see that it is easy to possibly set your machine up with incorrect tension and not even know it’s happening.
Side Effects of Incorrect Tension Settings
What are the side effects of having incorrect tension settings?
- Media skewing
- Media buckling
- Head strikes
- Inconsistent job lengths
Keep in mind that almost all of the roll to roll ValueJet’s with adjustable tension have two separate roll holders so it is important to adjust both of them to the same setting and not just set one as that will cause uneven tension.
Uneven tension is one of the more common occurrences and can cause any of the above-listed side effects. So if you are experiencing any of them and your machine has adjustable tension then it might be a good idea to take a look at the back of your printer to see how your roll holders are set. Also, the phrase “more is not always better” applies to media tension as well. Sometimes too much tension can put excess strain on your machine and material which can cause head strikes, media buckling or your jobs to come out different lengths due to grit roller slippage. But this isn’t the case with all materials, some materials like a little tension and run better through the machine with a little drag behind it so you will have to test your machine and material to see what best suits your needs.
If you thought the roll holders were the only place where tension can be added then think again! Our optional HD take-up system has additional weights that can be added to them to either add or reduce the tension so it’s always best to check the user manual if you are unsure about all the different tension settings for your machine.
Load Media The Right Way on a ValueJet
No More Bad Tension – Just Good Tension
Media tension may not sound like it’s on the top of the list of how to make good prints but it is definitely an important subject and can certainly make the difference when trying to get the best output possible. So the next time you get a head strike don’t tense up, relax and check your media tension!
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Shockingly Clean – The Static Battle
Shockingly Clean – The Static Battle
by Chris Padilla, Product Manager, Eco-Solvent MUTOH
Every printer out in the world needs electricity to run otherwise they would all just be very expensive
paperweights but what about the unwanted electricity that some of us don’t even know is being put into our machines? What do I mean you ask? Have you ever grabbed a roll or piece of material that has felt like it has made every single hair on your arm stand up? If you are like me and you have, then I’m sure you know that static is to blame for this.
Static can cause all kinds of unwanted issues on your machine such as print anomalies, importing excessive debris into the machine or even electrical failures. Keeping your machine free and clear of static can save you the headache of having those kinds of problems.
(Bottom of the print head when static is present on material)
Some helpful tips to prevent static in your work area are:
- Use static removal products to remove static off of the material before it goes into the machine. Here at Mutoh https://www.mutoh.com/ we use Staticide https://www.aclstaticide.com/ but there are many other options out there.
- Keep a controlled humidity environment where the printer is located. Less humidity in the air can cause an excess of static.
- If possible keep your machine on a hard surface floor. Carpet flooring can generate static when you are walking across it. Hard surface flooring can reduce the amount of static when walking around.
- Install an antistatic ionizing bar on your machine. Though Mutoh does not sell any antistatic ionizing bar’s, they are very effective at eliminating static and can be sourced from many manufacturers.
We should all always be on the lookout for preventative maintenance to keep our investments running. Following these simple tips can greatly reduce the risk of the side effects of static and help keep your Mutoh machine running clean and efficient for many years to come so jump on the bandwagon of keeping your equipment shockingly clean.
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3 Reasons You Should Think About Printer Maintenance
by Mike Springan, Product Manager/Techincal Trainer, MUTOH AMERICA
Why Talk About Printer Maintenance?
The idea of maintaining any product or piece of equipment you purchase to keep it working at its best is not a new concept. There are many articles and blogs dedicated to the best practices to maintain your wide format printer, easily found by simply googling “printer maintenance”. Most of these articles will compare your printer maintenance to maintenance you regularly perform on your car, and rightfully so. Both are significant purchases that you want to keep working at their best and, probably more important, at their most reliable state. Let’s face facts here, there is not much difference in getting in your car in the morning only to find the battery is dead and the car won’t start and arriving at your shop to find you print head is clogged and the printer won’t print.
Here are a few ideas that you can easily implement into your maintenance routine to help keep your printer in tip-top shape and the profits flowing!
1. A Clean Printer Is a Happy Printer
It is very easy to compare the most basic maintenance routines of your printer to that of your car or truck. Most people will wash their cars from time to time, change the oil and filter, wash windows, vacuum the interior, etc. etc. Your printer will operate at its best and most reliable state when you spend just a minimal amount of time cleaning it. It’s always best to follow the manufacturer’s guidelines and instructions for proper cleaning procedures.
Do a Nozzle Check Daily
The best way to make sure that when you arrive at your shop in the morning and print your first nozzle check with all nozzles firing 100 percent is to keep your capping station and print head clean and free of drying ink and debris. I call this daily maintenance. Some manufacturers will specify daily, weekly, monthly, etc. This maintenance routine should be done daily. It takes about 2 minutes at the end of a hard day of printing and will save you a lot of money and downtime in the future. You can never clean too much!
Wipe Down the Printer
Make sure you keep your print bed and platen area clean. Ink and ink overspray gets everywhere and there is really no way of preventing it. All you can do is clean up any ink spills immediately and give the whole printer a good wipe down on a weekly basis.
Run the Printer Cleaning Cycle
Some printers have built-in automatic cleaning cycles to prevent nozzles from clogging and to keep all nozzles primed and ready to go. These cleanings are there to help maintain the reliability of the printer when you are not there. Make sure you set your timers appropriately for the ink type you are using.
2. Environmental (Non)-Disaster
The working space and environment the printer is in is just as important as keeping the printer clean.
What Is Your Room Like?
Most manufacturers will recommend a temperature and humidity range optimal for your printer. For the most part, this boils down to approx. 75˚F and 50% humidity. Keeping your printer in a space that can maintain these optimal ranges will not only ensure the printer functions properly but will also help in making sure your medias are not too saturated (too much humidity) which can cause cockling and head strikes, or too dry (too low humidity) which can cause static that affects accurate dot placement or possible damage to electronic components.
What Other Equipment is Near Your Printer?
One thing that is often overlooked is what other equipment is around your printer. Do you do a lot of woodwork or metal work in the same room or space as your printer? The dust, dirt, and debris created from these other pieces of equipment will easily be attracted to fans, vents, or filters on your printer. It won’t be long before your printer is filthy and may be damaged. (See “A Clean Printer Is a Happy Printer”)
3. Prevent, Prevent, Prevent!!
Once more, this compares directly with maintaining your vehicle.
Plan to Replace
Like a car, printers are mechanical devices with many moving parts that wear out over time. Changing parts on a preventative basis means extended reliability i.e. change your oil, tires, battery etc.
Manufactures will have a list of periodical replacement parts. The idea here is to replace parts before they fail. A printer manufacturer will have guidelines on what parts may need to be greased or lubricated on a periodic basis or replaced after so many hours of operation.
If you follow these three tips you are sure to keep your printer operating consistently day in and day out.
Just like taking care of your car, proper upkeep can prevent a host of problems in the future.
Let the Pros Help
Just remember to save the larger problems and repairs for your friendly neighborhood, certified service technicians. You won’t want to make things worse.
Key Takeaway
- Perform a daily nozzle check.
- Wipe down and clean the printer.
- Periodically run a cleaning cycle.
- Keep your environment stable.
- Plan to replace key components on your printer.
The MUTOH Advantage
Why not take advantage of the features of MUTOH printers? They are loaded with easy to use maintenance options as well as options to keep going even when issues do come up. MUTOH has the best reputation in service, repair, and training with experts on staff with years of industry experience. Visit our website to see all the advantages of a MUTOH. www.mutoh.com
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