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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
Click To Watch Video :
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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