Why do we need print paste automation?

Textile printers use dyes either in powder or liquid forms for their printing needs. In fact, 90 per cent of printers use only powder dyes, such as reactive and disperse powder dyes (though these have to be first dissolved before application, and always need to be prepared fresh before every application). Only 10 per cent of printers use liquid pigment dyes. Liquid dyes need separate storage tanks and need to be kept in constant circulation in order to avoid sedimentation and spoiling of the entire batch. So, in both cases the dye preparation process is one that requires care.

Other issues faced by printing department of the dye houses are:

  •          Excess prepared print paste goes waste

  •          Stored print paste becomes hard and cannot be made fluid again

  •          Large area is required for storing the ready paste carboys for the whole day's printing

  •          Human error in handling the print paste

  •          Inconsistency in paste preparation

           

Print right the first time with Color Service

These colour preparation challenges can be easily overcome by installing an appropriate automatic print paste dispensing system in a dye house in printing department. 

Color Service, a world leader in automatic dosing system, has an innovative solution that allows a printing department to use both powder and liquid dyes in the same dosing system. The Color Service automatic printing colour kitchen is composed of two main units - a thickener preparation unit and a paste dosing unit. Both units can work either in standalone mode or together.

Thickener preparation unit

Thickeners such as alginate, guar gum imparts stickiness to print paste so that it may be applied on the fabric surface without bleeding and it helps in maintaining design outline.

Thickener preparation for printing requires special care. The addition of chemicals needs to be precise and the viscosity needs to be maintained in order to ensure good quality print (manual addition of chemicals can change the composition of the mix). When thickeners are mass produced and stored for a long time, it may affect the viscosity and render the whole mix useless. Hence, the best practice is to make fresh thickener daily as per the expected consumption. 

The thickener preparation unit from Color Service cooks the thickener automatically with minimum manual intervention. All powder and liquid ingredients can be dispensed automatically and can work with different recipes. The unit is equipped with fibreglass silos (supplied by Color Service) for powder chemicals and liquid chemical dispenser to add powders and liquids in to the mixture. The unit not only allows setting the quantity but also the order of powders and liquids that needs to be added in the mix. A powerful stirrer along with a scraper stirs the mix perfectly and gives a homogenous thickener. The thickener is delivered to a storage tank via a gear pump and a collector.