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18/10/2019 1www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Direct Inkjet Printing
The Technology that is replacing established Production Methods?!
Marco Rueckl | Sales Manager
18/10/2019 2www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
ZIMMER AUSTRIASince 1874 in textile printing industry. Since more than 40 years digital!
18/10/2019 3www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
ZIMMER AUSTRIA | Milestones
1874 Foundation of Franz Zimmer at Warnsdorf (North Bohemia/ K&K monarchy) 1950 Re-establishment of Zimmer in Kufstein (Austria)1951 Duplex screen printer1952 MAGNOPRINT (Flat screen printer)1955 ROTASCREEN (Rotary screen printer)1956 Invention of Zimmer magnet system1960 Establishment of Johannes Zimmer Klagenfurt1962 MAGNOROLL (coating machine for technical textiles & fabrics)1962 TDA (Flat screen printer for carpets)1976 Development of digital carpet printing system2005 CHROMOJET 25 dpi (high res. digital carpet printer)2009 CHROMOJET 76 dpi (process color printing)2010 COLARIS for home textiles, fashion, flags and banners …2012 COLARIS-NF Digital Printing Line for Narrow Fabrics2015 COLARIS.INFINITI 2015 COLARIS.CARPET (digital inkjet carpet printer)2016 Technology Center in Kufstein for textiles & flooring products
18/10/2019 4www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
ZIMMER AUSTRIA | Locations
ZIMMER AUSTRIA Kufstein | Digital Printing Systems is the digital competence centerfor textile, narrow fabric and carpet printing machines as well as system supplier forcarpet coating lines and digital functionalization systems.
ZIMMER AUSTRIA Klagenfurt | Screen Printing & Coating Systems provides all screenprinting and coating machines, as well as hot air dryers, heat treatment machines andloop steamers. The lines are adapted, designed and manufactured according to therequirements of our customers.
18/10/2019 6www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
FLOOR COVERINGS
TEXTILE PRINTING
Business segments at ZIMMER AUSTRIA Kufstein
SPECIALITIESDIGITALFUNCTIONALIZATION
NARROWFABRICS
18/10/2019 8www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Digital Printing Systems | CHROMOJET & COLARIS
COLARIS.INKJET PRINTINGCHROMOJET.VALVEJET PRINTING
18/10/2019 9www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
From VALVEJET to INKJET
2006HSV800
76 dpi
1982HGV09
8 - 16 dpi
1994HSV200
16 dpi
2005HSV400
25 dpi
2014StarFire SG1024
400 dpi
SPOT COLOR PRINTING PROCESS COLOR PRINTING12 to 14 colors
CMYK PRINTING
18/10/2019 10www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Direct Inkjet PrintingThe Technology that is replacing
established Production Methods?!
18/10/2019 11www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Topic & Content
Inkjet printing is able to imitate results of conventional methods:
• to bring color on a substrate
• to coat a substrate
What kind of methods?
Offset Printing
Screen Printing
Weaving
Tufting
Knitting Dyeing
Padding
Knife Coating
Spraying
standard revolutionary
Needlepunching
18/10/2019 12www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #1Jacquard Weaving of Carpets
18/10/2019 13www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #1
Jacquard Weaving of CarpetsBring Color on a Substrate
picture: www.woolcarpets.store
woven carpet rugs
18/10/2019 14www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #1
Jacquard Weaving of CarpetsBring Color on a Substrate
picture: www.vandewiele.be
Jacquard weaving loom
18/10/2019 15www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #1
Jacquard Weaving of CarpetsBring Color on a Substrate
picture: www.vandewiele.be
Jacquard weaving loom with colored yarn coils
18/10/2019 16www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #1
Jacquard Weaving of CarpetsBring Color on a Substrate
picture: www.vandewiele.be
warp and weft threads
18/10/2019 17www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #1
Jacquard Weaving of Carpets➔ Digital Printed!Bring Color on a Substrate
customer show room printed with COLARIS and disperse inks
18/10/2019 18www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #1
Jacquard Weaving of Carpets➔ Digital Printed!Bring Color on a Substrate
print imitates Jacquard structure penetration is key
18/10/2019 19www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #1
Jacquard Weaving of Carpets➔ Digital Printed!Bring Color on a Substrate
designs with thousands of colors and fine gradations
18/10/2019 20www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #1
Jacquard Weaving of Carpets➔ Digital Printed!Bring Color on a Substrate
COLARIS printing linefor woven PES carpets
18/10/2019 21www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #1
Jacquard Weaving of Carpets➔ Digital Printed!Bring Color on a Substrate
COLARIS digital inkjet printer in 4.2m (13ft) width
18/10/2019 22www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Pros/Cons of digital printing:
no more pre-colored yarn on stock
no limitations in number of colors
no limitation in repeat sizes
much finer resolution
higher production speed
lower investment in machinery
less penetration➔ but still good enough
post-washing is needed➔ but also yarn has to be washed
Case Study #1
Jacquard Weaving of Carpets➔ Digital Printed!Bring Color on a Substrate
18/10/2019 23www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #2Needlepunching of Nonwovens
18/10/2019 24www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #2
Needlepunching of NonwovensBring Color on a Substrate
picture: www.hunterdouglasarchitectural.eu
nonwovens as style and acousticceiling elements
18/10/2019 25www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #2
Needlepunching of NonwovensBring Color on a Substrate
picture: www. acoufelt.com
nonwovens as style and acousticwall & ceiling panels
18/10/2019 26www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #2
Needlepunching of NonwovensBring Color on a Substrate
picture: www.hunterdouglasarchitectural.euwww. acoufelt.com
solid color palettes
18/10/2019 27www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #2
Needlepunching of NonwovensBring Color on a Substrate
picture: www. andritz.com
needlepunch production line needleloom
18/10/2019 28www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #2
Needlepunching of NonwovensBring Color on a Substrate
picture: www. andritz.com
for coloration pre-dyed staple fibers are used, either of one color or mixing more colors for effects
18/10/2019 29www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #2
Needlepunching of Nonwovens➔ Digital Printed!Bring Color on a Substrate
customer acoustic panels (raw material)
18/10/2019 30www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #2
Needlepunching of Nonwovens➔ Digital Printed!Bring Color on a Substrate
printed with COLARIS and pigment inks
18/10/2019 31www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #2
Needlepunching of Nonwovens➔ Digital Printed!Bring Color on a Substrate
various constructions and thicknessesany kind of color and shade is possible
18/10/2019 32www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #2
Needlepunching of Nonwovens➔ Digital Printed!Bring Color on a Substrate
3D effects
18/10/2019 33www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #2
Needlepunching of Nonwovens➔ Digital Printed!Bring Color on a Substrate
imitation of other materials (concrete, wood, metal etc.)
18/10/2019 34www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #2
Needlepunching of Nonwovens➔ Digital Printed!Bring Color on a Substrate
imitation of multi-color needlepunch no limits in level of detail (scale in mm)
18/10/2019 35www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #2
Needlepunching of Nonwovens➔ Digital Printed!Bring Color on a Substrate
COLARIS line for roll-to-roll printing on nonwovens, up to 5.2m (17ft) width
COLARIS for printing on piece goods (panels & tiles)
18/10/2019 36www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #2
Needlepunching of Nonwovens➔ Digital Printed!Bring Color on a Substrate
Pros/Cons of digital printing:
no more pre-colored staple fibre on stock
quick change of color
no limitations in number of colors
any design pattern is possible
additional investment in printing machinery
less penetration➔ but probably not needed (e.g. wall panels)
lower fastness➔ but probably not needed (e.g. ceiling panels)
18/10/2019 37www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #3Indigo Dyeing of Denim
18/10/2019 38www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #3
Indigo Dyeing of DenimBring Color on a Substrate
picture: www.pinterest.com
blue jeans are available in an uncountable variety of color and style
18/10/2019 39www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #3
Indigo Dyeing of DenimBring Color on a Substrate
picture: www.pinterest.com
indigo blue is used for dyeing denim fabrics, it is a vat dye (kind of a non-soluble pigment)
18/10/2019 40www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #3
Indigo Dyeing of DenimBring Color on a Substrate
picture: www.seu.edu.bd
washing process is key to make the look of a typical blue jeans
18/10/2019 41www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #3
Indigo Dyeing of DenimBring Color on a Substrate
picture: www.wwt.com
the downside of today‘s denim process:impressive impact on environment and humans
18/10/2019 42www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
JETTEX INDANTHREN INKS
and the digital VAT printing process havebeen developed by DyStar and ZIMMER AUSTRIA.
The goal is to make DIGITAL VAT printing availableto the industry and to open new opportunities for the high-end printing industry. It is for sure thatvat dyes are in many cases the better alternative toreactive and pigment dyes when it comes to printon viscose fibers.
• Indigo blue is part of the vat dye family.• The vat dye is printed in form of a pigment.• During the padding and steaming process the pigments are transferred
into a liquid form (soluble in sodium hydrosulfide) and enter the cellulose fiber. • During the oxidizing step vat dye is transferred back into its insoluble form.
Case Study #3
Indigo Dyeing of Denim ➔ Digital Printed!Bring Color on a Substrate
18/10/2019 43www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #3
Indigo Dyeing of Denim ➔ Digital Printed!Bring Color on a Substrate
COLARIS printing line for2-phase VAT printing
18/10/2019 44www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #3
Indigo Dyeing of Denim ➔ Digital Printed!Bring Color on a Substrate
imitating denim look with samefastness properties of conventional process
18/10/2019 45www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #3
Indigo Dyeing of Denim ➔ Digital Printed!Bring Color on a Substrate
Pros/Cons of digital printing:
no more pre-colored yarn on stock
much lower water consumption
any effect can be printed without additional effort
quick and reproducible results
jeans are white on the inside
haptic is not same as original denim
18/10/2019 46www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #4Pre-/Post-Treatment of Fabrics
18/10/2019 47www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #4
Pre-/Post-Treatment of FabricsCoating a Substrate
Purpose of pre-/post-treatments:
• to improve color brilliancy➔ e.g. thickener for acid printing
• to improve printing definition➔ e.g. binder for pigment printing
• to improve fastness➔ e.g. polyurethane for crocking
• to enable fixation process➔ e.g. urea for reactive printing
• to add functionality➔ e.g. water repellency
UN-TREATED FABRIC PRE-COATED FABRIC PRE- & POST-COATED FABRIC
Example for PIGMENT PRINTING
18/10/2019 48www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #4
Pre-/Post-Treatment of FabricsCoating a Substrate
Standard method for pre-/post-treatment:
Padding
picture: www.kusterstextile.com
typical pick-up ratio in a padderis 60-100% of fabrics weight
18/10/2019 49www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #4
Pre-/Post-Treatment of FabricsCoating a Substrate
More intelligent methods of pre-/post-treatment:
(1) Knife Coating
(2) Foam Coating
(3) Screen Coating
(4) Magnet Roll Coating ➔MAGNOROLL, a ZIMMER patent
(1) (2) (3) (4)
18/10/2019 50www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #4
Pre-/Post-Treatment of FabricsCoating a Substrate
More intelligent method of pre-/post-treatment:
Spraying
picture: www.swift-jet.com
18/10/2019 51www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #4
Pre-/Post-Treatment of Fabrics➔ Digital Printed!Coating a Substrate
The revolutionary method of pre-/post-treatment:
Digital Printing
picture: www.researchgate.net
18/10/2019 52www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #4
Pre-/Post-Treatment of Fabrics➔ Digital Printed!Coating a Substrate
= + + +
RGB K C M Y
jetable fluid(either pre- or post-treatment)
consumption isequal to ink laydown!
18/10/2019 53www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #4
Pre-/Post-Treatment of Fabrics➔ Digital Printed!Coating a Substrate
• Digital jetting of pre-coat and post-coat only where it is needed!
• Same printer will be used for coating chemistry as for color.
• Reducing the number of process steps will be the real revolution in the industry!
• Everything will become digital ➔ no limits with the right machinery setup!
18/10/2019 54www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
PRE-Coating
Drying PRINTING DryingPOST-
CoatingDrying
COLARIS PRINTING with inline PRE-/POST-Coating
Drying
Case Study #4
Pre-/Post-Treatment of Fabrics➔ Digital Printed!Coating a Substrate
PIGMENT PRINTING
COLARIS pigment printing line with inline pre-/post-treatment via jetable fluids
18/10/2019 55www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
What is needed for printing:
• cirulation system for jetable fluids➔ e.g. StarFire print head technology
• temperature control system to assure best jetting behaviour
• variety of drop sizes to cover different types of substrates
Case Study #4
Pre-/Post-Treatment of Fabrics➔ Digital Printed!Coating a Substrate
COLARIS circulation system for jetable fluids COLARIS temperature control system
18/10/2019 56www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
PRE-Coating
Drying PRINTING Drying Steaming Washing Drying
CHROMOJETinline PRE-Coating
COLARIS PRINTING
Steaming Washing Drying
REACTIVE PRINTING
Case Study #4
Pre-/Post-Treatment of Fabrics➔ Digital Printed!Coating a Substrate
reactive towel printing line with COLARIS (4) and CHROMOJET inline pre-treatment system (3)
18/10/2019 57www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
How does it work:
• paste of thickener, urea, bi-carbonate etc.
• application is done digitally and can be adjusted to the substrate
• pre-treatment is controllable in regards to penetration and concentration
What is needed for printing:
• robust nozzle technology➔ e.g. CHROMOJET valvejet technology
• variety of nozzle sizes to cover different types of substrates
Case Study #4
Pre-/Post-Treatment of Fabrics➔ Digital Printed!Coating a Substrate
CHROMOJET printing module for jetting pre-treatment pastes
18/10/2019 58www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #4
Pre-/Post-Treatment of Fabrics➔ Digital Printed!Coating a Substrate
Pros/Cons of digital printing:
reduced number of process steps
combination of different chemistry in one step
much less chemistry consumption
much less drying capacity
better hand
lower investment in machinery
less post-washing
higher price of chemistry➔ but consumption jetable fluids
lower continous speed➔ but single-pass printer could compete
sometimes lower effect of coating
18/10/2019 59www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
(1) breathable membrane(2) antibacterial(3) soil release finish(4) pattern printing(5) photochromic effects
The future of textiles:
Digital Functionalization!
Case Study #4
Pre-/Post-Treatment of Fabrics➔ Digital Printed!Coating a Substrate
18/10/2019 60www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
And we are not that far away!
Case Study #4
Pre-/Post-Treatment of Fabrics➔ Digital Printed!Coating a Substrate
picture: www.pireta.co.uk
smart textiles, printed with CHROMOJET technology
18/10/2019 61www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
Case Study #4
Pre-/Post-Treatment of Fabrics➔ Digital Printed!Coating a Substrate
picture: www.pireta.co.uk
smart textilesprinted with CHROMOJET technology
18/10/2019 62www.zimmer-austria.com www.zimmer-kufstein.com
ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS
ZIMMER AUSTRIAMarco Rueckl
Sales Manager | ZIMMER AUSTRIA Kufstein+43 664 886 899 64 | m.rueckl@zimmer-austria.com
CREATING SUCCESS STORIES40 YEARS OF DIGITAL PRINTING
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