case study in textile printing

8/3/2019 Case Study in Textile Printing

http://slidepdf.com/reader/full/case-study-in-textile-printing 1/33

Case Studies

Mr. Leon Moser

Moderator: Ms. Rita Hindle

2B



CASE STUDIES

FOR

TEXTILE PRINTING



Textile Printing- The application of color to a fabric in

a design or pattern (localized dyeing)

Modern printing generally incorporates one of the followingtechniques:

1. Flat-bed Screen Printing

2. Rotary Screen Printing

3. Engraved Roller Printing

4. Heat Transfer Printing



FLATBED SCREEN ROTARY SCREEN ROLLER HEAT TRANSFER

-WOVENS, SOME -WOVENS & KNITS -WOVENS -KNITS

KNITS

-SLOW

-IMPROVING

DETAIL

-LARGE

REPEATS

-VERY FAST -FAST -SLOW

-BETTER DETAIL -EXCELLENT -EXCELLENT

DETAIL DETAIL

-SMALL REPEATS-EXPENSIVE

-GREAT FOR

ROLLERS SMALLYARDAGES

-LONG RUNS



WAS T E C HAR AC T E RI S T I C S F OR T E XT I L E P R I NT I NG

Ha r d t o T r e a t Wa s t e s

Color from Dyes or Pigments

Toxic Organic Ch e mi c a l s

Me t a l s

P h o s p h a t e s

Di s p e r s i b l e Wa s t e s

Print P a s t e Co mp o n e n t s

Thickeners, Binders, Humectants, etc.

Hazardous or T o x i c Wa s t e s

Me t a l s

Or g a n i c S o l v e n t s

Hi g h Vo l u me Wa s t e s

Scour a n d Afterwash Water

( H o t , Warm a n d Co l d )



MAI N P R OB L E MS I N P R I NT I NG

COLOR - Dy e a n d P a s t e Du mp s ; Cl e a n - u p s

METALS - Dy e Du mp s ; Screen Ma k i n g ; P h o t o De v e l o p i n g

S U S P E NDE D S O L I DS - Print P a s t e a n d Clear Discards

S O L V E N T S - Emulsion Thickeners a n d Cl e a n - u p s

HOT WATER - Af t e r wa s h i n g

BOD - De s i z i n g ; P r i n t P a s t e a n d Clear Di s c a r d s

F OAM ( F l o a t i n g S o l i d s ) - Carpet P r i n t i n g



STEPS IN PRINTING PROCESS

1. Preparation of Print Paste

2 Printing of Fabric

3. Drying

4. Fixation of Dyestuff

5. Washing - off



fiber,the colorant system used, to some extent,the

type of printing machine.

binders, cross-linking agents

dispersing agents - surfactants

water-retaining agents (humectants)adhesion promotersdefoamers

catalystshand modifiers



DYE S T UF F S US E D I N P RI NT I NG

S A ME A S T H OS E U S E D I N DY E I N G

S P E C I A L R E Q U I R E ME N T S

H I G H S O L UB I L I T Y , D I S P E R S I B I L I T Y

E X C E L L E N T WE T F A S T N E S S

C O T T O N - R E AC T I VE S , V A T S , N A P H T H O L S

WOOL - ACI D, ME T AL I Z E D

N Y L O N - ACI D, ME T AL I Z E D

A C R Y L I C - CAT I ONI C

A C E T A T E - DI S P E R S E , C AT I ONI C

T R I A CE T A T E - D I S P E RS E

P O L Y E S T E R - D I S P E RS E

QI ANA - ACI D, DI S P E RS E



AUXILIARY CHEMICALS

T H OS E NE C E S S A RY F OR F I X AT I O N O F DY E I N T O F I B E R

R E A CT I VE S - AL K A L I

V A T S - RE D UC I N G AGENT

A C I D S - ACI D

CAT I ONI C - ACI D

D I S P E R S E - CAR RI E R

Do NO T I NC OR P O RAT E S T R ONG AC I D , B AS E S , OXI DI Z I NG AND REDUCING

AGE NT S I N P RI NT P A S T E .

ACI D AGE R

L A T E N T R E D UC I N G AG E N T S

( S O DI U M S U L F O X Y L A T E F O R M A L D E H Y D E )



Water-in-oil

Polyacrylic Acid (Acrylics)

EMA (Monsanto)

Mixed Monomer Thickeners



T H I C KE N I NG AGE N T S

MU S T H A V E PSEUDOPLASTIC FLOW BEHAVIOR

L o w S HEAR = H I G H V I S C O S I T Y

HI GH S HEAR = L O W VI S C OS I T Y

P S E U D O P L A S T I C B E H A V I O R



A product of high molecular weightwhich is

capable of forming a three-dimensional film used to

hold the pigment particles in place on the surface of a

textile substrate.

-not necessary when using dyes

-very important in determining fastness



EDTA - most popular to use with dyes

Ca l g o n - o f t e n u s e d t o s o f t e n wa t e r



Dispersing agents

Surfactats - used to disperse solid particles,

promote paste stability, and increase paste penetration

into the fiber.

Similar in use are protective colloids-

increasing paste stability.



Humectants

Materials added to

print paste formulations

print paste formulations to

to prevent water evaporation



Increase adhesion of binder system to substrate

i.e. Pigment printing of fiberglass is enhanced

by using aminosilane



C a t a l y s t s

A chemical formulation to increase the

speed of a chemical reaction.



Ha n d Mo d i f i e r s

No r ma l l y s o f t e n e r s because binders tend to

stiffen the fabric.



R E AS ONS F OR S C OUR I NG

R E MO VE T H E T H I C KE N I NG AG E NT

R E MOVE A UXI L I AR I E S

R E MOV E E X C E S S D YE S T U F F

I MP R OVE BR I L L I ANC E OF P R I NT

I MP R OVE F AS T N E S S P R OP E R T I E S OF

P R I NT

P R O B L E M-

B AC K S T A I NI N G O F U NDY E D A RE A S



C AS E S T U DI E S F O R T E XT I L E P R I NT I NG

C AS E N O. 1

De s c r i p t i o n - A s u r v e y o f d y e s i n t h e mi d 1 9 7 0 ' s s h o we d

t h a t 9 5 % o f t h e c a p p e r i n a n N. C. c o mp a n y ' s e f f l u e n t

o r i g i n a t e d f r o m 1 3 d y e s . T h e y w e r e :

Dy e

Be l a mi n e F Re d 3 B L

Be l a mi n e B Bl u e L TP y r a z o l F Vi o l e t MXD

S o l a n t i n e B r o wn BRL

At l a n t i c B l u e 8 GL N- K

At l a n t i c Re s i n f a s t Bl u e 2 R

S i r i u s S u p r a T u r q u o i s e L G

S u p e r l i t e f a s t Bl u e 2 GL L

Di r e c t Na v y OF S

Be l a mi n e Re d 3 BL

S o l o p h e n y l Br o wn B RL

F a s t o l i t e Bl u e L

At l a n t i c B l a c k NR

P e r c e n t a g e C u Co n t e n t

4 . 0 0

3 . 6 8

3 . 0 0

3 . 0 0

2 . 7 0

2 . 5 0

2 . 2 9

1 . 0 0

0 . 7 0

4 . 0 0

3 . 0 0

2 . 7 0

1 . 5 0



Al l o f t h e p r e v i o u s d y e s h a v e c o p p e r a s a p a r t o f t h e

d y e mo l e c u l e s t r u c t u r e .

P o s s i b l e C o u r s e s o f Ac t i o n :

( 1 ) S u b s t i t u t e f o r me t a l c o n t a i n i n g d y e s wi t h n o n -

me t a l d y e s .

( 2 ) I n s u r e ma x i mu m f i x a t i o n o f d y e b y o p t i mi z i n g

a l l p r o c e s s i n g p a r a me t e r s s u c h a s t i me a n d t e mp e r a t u r e o f

f i x a t i o n , p H, s a l t c o n c e n t r a t i o n , a n d a u x i l l a r y c h e mi c a l s

c o n t e n t .

I n t h i s c a s e , d i r e c t d y e s wi t h n o n - me t a l c o n t e n t we r e

s u b s t i t u t e d wh e r e p o s s i b l e , t h e r e f o r e , r e d u c i n g t h e me t a l

c o n t e n t d i s c h a r g e d .



P I GME NT S I N T E XT I L E P R I NT I NG

I n s o me c a s e s , t e x t i l e p r i n t i n g c o mp a n i e s ma y u s e

me t a l c o n t a i n i n g p i g me n t s wh i c h ma y n o t a p p e a r i n t h e

Co l o r I n d e x . He r e a l s o t h e c o p p e r i s b o u n d a s a n i n t e g r a l

p a r t o f t h e c h r o mo p h o r e mo l e c u l e .

P i g me n t P e r c e n t a g e & Co n t e n t

I n mo n t Re s p a d Gr e e n GB3 W 0 . 8 0

I n mo n t Re s p a d B l u e G 3 W 1 . 4 0

I n mo n t Re s p a d Bl u e GH3 W 1 . 3 5

I n mo n t Re s p a d B l u e GL 3 W 0 . 1 0

I n mo n t Re s p a d Vi o l e t V3 W 1 . 1 5

I n mo n t Re s p a d Gr e y R 3 W 0 . 1 0



C AS E S T UDI E S F OR T EXT I L E P R I NT I NG

C AS E N O. 2

De s c r i p t i o n - P CA I n t e r n a t i o n a l , I n c . i s a c o l o r p o r t r a i t

p r o c e s s i n g f i r m. P CA h a s u n d e r t a k e n a n u mb e r o f p r o j e c t s

t o r e c o v e r a n d r e c y c l e p r o c e s s wa s t e e s p e c i a l l y s i l v e r

r e c o v e r y .

Co u r s e s o f Ac t i o n :

( 1 ) An e l e c t r o l y t i c r e c o v e r s s i l v e r f r o m t h e c o l o r

n e g a t i v e f i l m f i x e r s o l u t i o n s . T h e p r o c e s s r e s u l t s i n a

9 6 % r e u s e o f t h e f i x e r s o l u t i o n s .

( 2 ) Co l o r d e v e l o p e r i s r e g e n e r a t e d u s i n g a n i o n

e x c h a n g e s y s t e m. T o t a l p r o c e s s i n g r e s u l t s i n a n 8 4 %

r e c o v e r y o f t h e c o l o r d e v e l o p e r s o l u t i o n .

( 3 ) S p e n t b l e a c h s o l u t i o n s a r e r e c o v e r e d a n d

r e g e n e r a t e d b y c h e mi c a l a d d i t i o n s , a t t a i n i n g 9 0 % r e u s e

c a p a b i l i t y .

S a v i n g s :

P CA s a v e s o v e r $ 1 . 1 mi l l i o n e a c h y e a r i n r e u s i n g

p r o c e s s s o l u t i o n s .S i l v e r r e c o v e r y a d d s a n o t h e r

a p p r o x i ma t e $ 8 0 0 , 0 0 0 p e r y e a r .

As c a n b e s e e n , t h i s s t u d y e a s i l y r e l a t e s t o t h e

p h o t o g r a p h i c p r o c e s s e s u s e d i n t e x t i l e p r i n t i n g s c r e e n

d e s i g n a n d ma n u f a c t u r e .



CAS E S T UDI E S F OR T EXT I L E P R I NT I NG

C AS E N O. 1

D e s c r i p t i o n : Ame r i c a n Co l o r s c o a t s o r p r i n t s o n f i b e r g l a s s .

Wa s t e a c e t o n e i s g e n e r a t e d d u r i n g t h e c o a t i n g o r p r i n t i n g

p r o c e s s .


( 1 ) Wa s t e a c e t o n e i s d i s t i l l e d a n d r e c o v e r e d a t

a p p r o x i ma t e l y a 7 0 % r a t e .T h i s r e c l a i me d s o l v e n t i s u s e d

i n e q u i p me n t c l e a n u p .

( 2 ) T h e v o l u me o f s o l v e n t h a s b e e n r e d u c e d b y p r o c e s s

mo d i f i c a t i o n s , e s p e c i a l l y g o i n g f r o m l i g h t t o d a r k c o a t i n g s .

T h i s y i e l d s a n o v e r a l l r e d u c t i o n i n c l e a n u p wa s t e .

S a v i n g s :

Ame r i c a n Co l o r s c u t p r o d u c t i o n c o s t s b y r e d u c i n g v o l u me s

o f wa s t e s o l v e n t a n d r e c l a i mi n g wh a t s o l v e n t wa s t e wa s

g e n e r a t e d . T h e n e t s a v i n g s we r e ma n y t h o u s a n d s o f d o l l a r s

p e r y e a r .



CAS E S T UDI E S F OR T E XT I L E P R I NT I NG

C AS E N O. 4

De s c r i p t i o n : T h i e l e - E n g d a h l , I n c . u s e s p r i n t i n g i n k s .

I n e q u i p me n t c l e a n u p t h e c o mp a n y u s e s i s o p r o p y l a c e t a t e .

Co u r s e s o f Ac t i o n

T h i e l e - E n g d a h l u s e s s o l v e n t t wi c e f o r c l e a n u p b e f o r e

r e c o v e r y a n d r e u s e . T h e s o l v e n t i s r e c o v e r e d o n - s i t e

u s i n g b a t c h d i s t i l l a t i o n . Di s t i l l a t i o n b o t t o ms a r e s e n to f f - s i t e f o r d i s p o s a l .

S a v i n g s :

Be f o r e t h e d i s t i l l a t i o n s y s t e m t h e c o mp a n y s e n t 5 , 0 0 0

g a l l o n s o f u s e d s o l v e n t t o o f f - s i t e d i s p o s a l e v e r y 4 5 d a y s .

S i n c e r e c l a i mi n g a n d r e u s e r e d u c e b o t h t h e v o l u me o f wa s t e

a n d t h e v o l u me o f v i r g i n s o l v e n t s p u r c h a s e d , s i g n i f i c a n t

s a v i n g s r e s u l t , p a y i n g f o r t h e d i s t i l l a t i o n s y s t e m i n 2

y e a r s .



CAS E S T UDI E S F OR T E XT I L E P R I NT I NG

C AS E N O. 5

De s c r i p t i o n : L e n o i r Mi r r o r C o . u s e s x y l e n e s o l v e n t i n

e q u i p me n t c l e a n u p .


T h e c o mp a n y r e d u c e d t h e i r wa s t e c o s t s b y r e c o v e r i n g

a n d r e u s i n g s p e n t s o l v e n t o n - s i t e . Ap p r o x i ma t e l y 9 5 %

s o l v e n t wa s r e c o v e r e d b y d i s t i l l a t i o n a n d s t i l l b o t t o ms

a r e s e n t t o a n i n c i n e r a t o r .

S a v i n g s :

L e n o i r Mi r r o r s a v e s o v e r $ 5 , 0 0 0 p e r y e a r i n ma t e r i a l

a n d d i s p o s a l c o s t s . T o t a l s y s t e m p a y o u t wi l l b e t h i r t e e n

mo n t h s .

T h i s o v e r a l l c a s e r e l a t e s t o s o l v e n t r e c o v e r y i n

p r i n t i n g f r o m s c r e e n a n d ma c h i n e c l e a n u p s .



C AS E S T UDI E S F O R T E XT I L E P RI NT I NG

C AS E N O. 6

De s c r i p t i o n : Ame r i c a n E n k a C o . ( n o w BAS F ) p r o d u c e s n y l o n

y a r n . I s o p r o p y l a l c o h o l wa s u s e d a s a s o l v e n t f o r a

f a t t y a mi n e . P r e v i o u s l y t h e c o mp a n y e mp l o y e d a n o u t s i d e

f i r m f o r t h e d i s t i l l a t i o n a n d r e u s e o f s o l v e n t . Av e r a g e

s o l v e n t l o s s e s we r e 1 5 % wi t h s o me a s h i g h a s 4 0 %. T h e

s o l v e n t wa s a l s o a f t e n c o n t a mi n a t e d a n d r e q u i r e d a n a l y s i s

b e f o r e r e u s e .


T h e c o mp a n y p u r c h a s e d a u s e d d i s t i l l a t i o n s y s t e m f o r

$ 7 , 5 0 0 . 0 0 S o me mo d i f i c a t i o n s we r e ma d e t o t h e u n i t f o r

u s e wi t h t h e i r p r o d u c t .

S a v i n g s :

I n i t i a l l y t h i s r e s u l t e d i n a $ 9 0 , 0 0 0 . 0 0 p e r y e a r

s a v i n g s o v e r t h e i r p r e v i o u s c o n t r a c t f e e s . T h e y a l s o

o b t a i n e d a mu c h s u p e r i o r r e c o v e r e d s o l v e n t a t a 9 0 %

e f f i c i e n c y r a t e . T h e y n o w u s e f a r mo r e o f t h e r e c o v e r e d

a l c o h o l a n d a l s o u t i l i z e t h e s t i l l b o t t o ms a s a n a s p h a l te mu l s i f i e r i n a n o t h e r p r o d u c t l i n e . T o t a l p a y b a c k f o r

t h e p r o j e c t wa s a p p r o x i ma t e l y o n e mo n t h .

T h i s p r o j e c t a l s o r e l a t e s t o s o l v e n t r e c o v e r y a n d

r e u s e p o s s i b l e b y t e x t i l e p r i n t i n g o p e r a t i o n s .



C AS E S T UDI E S F O R T E XT I L E P R I NT I NG

C AS E N O. 7

De s c r i p t i o n : Re x h a m Co r p . p r i n t s p r o d u c t l a b e l s u s i n g

a l c o h o l / a c e t a t e b a s e d f o r mu l a t i o n s u s i n g f l e x o g r a p h i c

p r i n t i n g t e c h n i q u e s .


T h e c o mp a n y wa s a b l e t o r e d u c e i t s wa s t e g e n e r a t i o n

t h r o u g h p r o c e s s mo d i f i c a t i o n . Re x h a m s u b s t i t u t e d wa t e r

b a s e d i n k s f o r t h e t r a d i t i o n a l s o l v e n t b a s e d ma t e r i a l s .

T h e n e t r e s u l t wa s t o r e d u c e t h e q u a n t i t y o f s o l v e n t wa s t e

g e n e r a t e d a n d t h e q u a n t i t y o f s o l v e n t r e l e a s e d t o t h e

a t mo s p h e r e . Ho we v e r , g l o s s f i n i s h l a b e l s c o u l d n o t b e

p r i n t e d t h i s wa y . T h e r e wa s a l s o a n e t d e c r e a s e i n

p r i n t i n g s p e e d u s i n g t h e wa t e r - b a s e d i n k s .

S a v i n g s :

T h i s mo d i f i c a t i o n d i d n o t r e q u i r e R e x h a m t o i n c u r

a n y l a r g e c a p i t a l c o s t s ; h o we v e r , s o me o p e r a t o r r e t r a i n i n g

wa s r e q u i r e d . Be c a u s e t h e c o mp a n y a l s o p u r c h a s e d a n o n -

s i t e d i s t i l l a t i o n s y s t e m f o r s o l v e n t r e c o v e r y f o r $ 1 6 , 0 0 0 ,

Re x h a m Co r p . s a v e s $ 1 5 , 0 0 0 p e r y e a r i n v i r g i n s o l v e n t c o s t s

a n d $ 2 2 , 8 0 0 p e r y e a r i n wa s t e d i s p o s a l c o s t s . T o t a l p a y -

b a c k f o r t h e p r o c e s s mo d i f i c a t i o n s a n d s o l v e n t r e c o v e r y

s y s t e ms wa s 5 mo n t h s .

As c a n b e s e e n , t h i s e x a mp l e r e l a t e s d i r e c t l y t o ma n y

t e x t i l e p r i n t i n g o p e r a t i o n s .



C AS E S T UDI E S F O R T E XT I L E P R I NT I NG

C AS E N O. 8

De s c r i p t i o n : RJ R Ar c h e r , I n c . i s a p a p e r p r i n t i n g

o p e r a t i o n . T h e c o mp a n y wa s h a v i n g a g r e a t d e a l o f

p r o b l e ms wi t h a i r e mi s s i o n s f r o m i t s p r i n t i n g p r e s s e s .


RJ R Ar c h e r i n s t a l l e d a c a r b o n a d s o r p t i o n s y s t e m t o

c a p t u r e a n d r e c o v e r 9 8 % o f t h e s o l v e n t s l o s t t o t h ea t mo s p h e r e f r o m d r y i n g o v e n s . T h i s a mo u n t e d t o a n a v e r a g e

o f 2 , 6 5 5 g a l l o n s p e r d a y . T h i s s o l v e n t c o u l d b e e i t h e r

r e u s e d o r s o l d . By p r o p e r l y r e c i r c u l a t i n g a i r e x h a u s t f r o m

i t s d r y i n g o v e n s b e f o r e d i s t i l l a t i o n , t h e s i z e o f t h e

s y s t e m wa s s ma l l e r t h a n o r i g i n a l l y p r e d i c t e d .

Ad d i t i o n a l l y , a l l i n k s f o r mu l a t i o n s we r e r e v i e we d a n d

r e f o r mu l a t e d u s i n g a ma x i mu m o f t wo s o l v e n t s p e r b l e n d ,

t h e r e f o r e i n c r e a s i n g t h e r e c o v e r y s y s t e m e f f i c i e n c y .

S a v i n g s :

RJ R Ar c h e r s a v e s o v e r $ 6 , 3 0 0 p e r d a y i n s o l v e n t c o s t s .

T h e p a y b a c k f o r t h e $ 4 . 3 mi l l i o n r e c o v e r y s y s t e m wa s 2 . 5

y e a r s . Af t e r p a y b a c k , RJ R Ar c h e r s e s t i ma t e d a n a n n u a l

$ 1 . 7 mi l l i o n n e t c o s t s a v i n g s .

Ai r e mi s s i o n s a r e a l s o v e r y i mp o r t a n t t o a n u mb e r o f

t e x t i l e p r i n t e r s .




C AS E N O. 7

De s c r i p t i o n : Un i t e d P i e c e Dy e Wo r k s i s a t e x t i l e d y e i n g

a n d f i n i s h i n g o p e r a t i o n l o c a t e d i n No r t h Ca r o l i n a . T h e

c o mp a n y b e c a u s e o f i t s p r o c e s s i n g o p e r a t i o n s h a d a

p r o b l e m wi t h p h o s p h o r o u s c o n t a i n i n g ma t e r i a l s i n i t s

e f f l u e n t .


T h e c o mp a n y wa s a b l e t o me e t s t r i n g e n t d i s c h a r g e l i mi t s

o n p h o s p h o r o u s b y ma k i n g c h e mi c a l s u b s t i t u t i o n s i n t h e i r

p r o d u c t i o n p r o c e s s e s . I n i t i a l l y , a d e t a i l e d c h e mi c a l

a n a l y s i s a n d e v a l u a t i o n o f t h e i r p r o c e s s i n g wa s p e r f o r me d

t o i d e n t i f y s o u r c e s o f p h o s p h o r o u s . Wh e r e p o s s i b l e , n o n -

p h o s p h o r o u s o r n o n - p h o s p h a t e c o n t a i n i n g c h e mi c a l s we r e

s u b s t i t u t e d .

S a v i n g s :

T h r o u g h t h i s s u b s t i t u t i o n , t h e u s e o f h e x a me t a p h o s p h a t e

wa s r e d u c e d a n d t h e u s e o f p h o s p h o r i c a c i d wa s t o t a l l y

e l i mi n a t e d .T h e l e v e l o f p h o s p h o r o u s i n t h e c o mp a n y ' s

e f f l u e n t wa s r e d u c e d f r o m 7 . 7 mg / l i t e r t o l e s s t h a n 1

mg / l i t e r . Un i t e d P i e c e Dy e Wo r k s wa s a b l e t o me e t t h e s e

e f f l u e n t l i mi t s wi t h o u t a n y c a p i t a l e x p e n d i t u r e f o r

p h o s p h o r o u s r e mo v a l o r q u a l i t y r e d u c t i o n i n t h e i r p r o d u c t s .




C AS E NO. 1 0

De s c r i p t i o n : E l l e n Kn i t t i n g Mi l l s , a No r t h Ca r o l i n a

h o s i e r y c o mp a n y , wa s d i s c h a r g i n g s p e n t d y e b a t h wa t e r t o

a mu n i c i p a l s e we r s y s t e m. T h e wa t e r t e mp e r a t u r e o f 1 3 0 ° F .

c a u s e d ma n y p r o b l e ms f o r t h e s e we r t r e a t me n t s y s t e m.


T h e c o mp a n y d e c i d e d t o p u r c h a s e a h e a t r e c l a i ma t i o ns y s t e m. T h i s t y p e s y s t e m i s g e n e r a l l y o n l y c o s t e f f e c t i v e

i f t h e r e i s a s u f f i c i e n t f l o w o f wa t e r a t a h i g h e n o u g h

t e mp e r a t u r e . T h e n e t r e s u l t o f t h i s a c t i o n wa s r e d u c e d

t h e r ma l p o l l u t i o n , r e d u c e d wa s t e t r e a t me n t c o s t s a n d

r e c o v e r y a n d r e u s e o f e n e r g y .

S a v i n g s :

T h e c o mp a n y i n v e s t e d $ 1 0 0 , 0 0 0 i n a h e a t r e c o v e r y a n d

e x h a n g e s y s t e m r e d u c i n g t h e e f f l u e n t t e mp e r a t u r e f r o m 1 3 0 ° F

t o 7 0 ° F . T h i s r e mo v e d h e a t wa s u s e d t o p r e h e a t i n c o mi n g

f e e d wa t e r f o r d y e t u b s f r o m 5 5 ° F . t o 1 0 5 ° F . T h i s

p r e h e a t i n g o p e r a t i o n a l o n e s a v e d a p p r o x i ma t e l y 5 2 , 0 0 0

g a l l o n s o f f u e l o i l p e r y e a r . T o t a l p a y b a c k f o r t h e s y s t e m

wa s t wo y e a r s .



CASE STUDIES FOR TEXTILE PRINTING

CASE NO. 11

Descr ipt ion: Kemp Furniture used several process

modif icat ions to reduce their overal l waste volume. As

a furni ture manufac turer , the t radi t iona l ly used solvent -

based inks to print wood grain on plywood and fiberboard.

Courses of Action:

With only minor changes in operating procedures, the

company substituted water-based inks for the solvent-based

inks.

Savings :

The net resul t of this ini t ia l change was to reduce

solvent waste by 30 - 40%. These waste solvents were

reused, where possible, to clean pumps and piping. This

was a l l accomplished with no major capi ta l out lay. Off-

site recovery of solvent was used and this solvent reused

in processing.

case study in textile printing

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