AOP Design

Development
&
It’s Print
Process

Author:
Md Shawkat Hossain (Sohel)
Manager:- CAD
Unifill Composite Dyeing Mills Ltd.

Lecture Sheet- 04
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A ll-over Printing vs all-over Digital Printing (Part-2)

In the first part, I discussed on ‘difference between ‘all-over printing’ and ‘all-over
digital printing’; Companies with AOP printing facility in Bangladesh; continuous
process flow chart for all-over digital printing; advantages and disadvantages of
digital printing, etc.

Figure 1: Bangladesh printing sector uses the best available all-over digital printing machines.

In the second (last) part, I will depict the history of all-over digital printing in
Bangladesh, popular all-over digital printing machines that are using by Bangladesh
textile industry; Major problems and solutions of digital printing, etc.

All-over digital printing in Bangladesh

All-over printing (AOP) project started its journey in the 1980s in an export oriental
factory of Bangladesh, and 2020, all-over the printing project has been running about
in 80 factories. Today, Bangladesh has gained the skill to compete with any country
in the world with AOP and has created a strong position. But we are still far behind in
all-over digital printing.

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Lacking efficient manpower, poor application technology, low-quality raw material
and poor fabric quality are the main reasons for this situation. Also, we do not have
any learning opportunities for digital printing technology. That is why fresher
graduates and experienced technologist cannot enrich their knowledge about digital
printing technology. Our competitors like China, Pakistan, and Turkey, etc. are growing
very fast in this industry.

For the first time in 2014, Beximco started all-over digital printing in the Bangladesh
textile industry. Now 20 factories in Bangladesh use all-over digital printing having
different brands, different facilities, and different production capacities. In our
country, most of the factories are using the machines of below six brands –

Reggiani Machine (Italy brand) is the best. Reggiani Machine’s print quality is good,
production speed is fast, and the operating system is easy as well. We need
diversification in the textile industry if we want to survive shortly. So, the investors
need to focus on digital technology as soon as possible.

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Here is a list of the factories in Bangladesh that have Digital All-over Printing
Machines:

Dird Composite Textile Ltd NAZ Bangladesh Ltd

Durst Alpha 190 Machine (Italy Brand) Zimmer Machine.
Reactive Print.04 Reactive Print.
Head: 64 Head :32
Head name: Kyocera Head name: Fuji Diamatix
Max.width:1900 mm Max width:1800 mm
Production capacity: 5000 m/day. Starfire-sa-1024
Knit production capacity: 1200-1300 kg Production capacity:3000 yds/day
Silver Line Composite Textile Ltd. Hossain Dyeing & Printing Limited.
Zimmer Homer digital print.
Reactive Print. Reactive print
Head:64 Head name: Kyocera
Max width:1800 mm Head: – 16
Head name: Fuji Diamatix starfire-sa-1024 Max width:60 inches
Production capacity:6000 yds/day Production capacity:2400 yds/day
Nice Fabrics Processing Limited. ACS Textiles (Bangladesh) Limited.
Attexco Machine (China) MS Machine (Italy Brand)
Reactive Print. Reactive Print.
Head: 32 Head:32
Machine(small) Max width:124 inch.
Max width: 35-72 inch Production capacity: 5000 yds/day
Machine (Big)
Max width: 35-100 inch
Print Capacity: 300 mtr per hour.
Jamuna Group. Pran RFL Chorka Textile
Reggiani Machine. (Italy Brand) Atexco Machine
Reactive Print. Reactive Print.
Head-16 Head-16
Max width: -70 Inch Day-64-inch max
Production capacity: 3500-4000 yds/day Production capacity: 2200 yds/day
Beximco Textile Division. Mondol Group.
Machine name: Reggiani (Brand Italy) Durst alpha 190 Machine (Italy Brand)
Print type: – Reactive print Reactive: Print.
Head-16 Head: 64
Head name: – Kyocera Max width: 74 inches
Color: 8 color Printable Color. 8 Knit
Max width: 72 inches Production capacity knit:1000 kg/day

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Production Capacity: Woven-3000 Woven: 5000 yds/day
yds/day. Knit – 500-800 kg/day
GMS Composite Knitting Industry Robintex Group.
Limited. Machine 1: Durst Alpha 190 Brand: Italy
Machine 1: Durst Alpha-330 (Italy Brand) Print type: Reactive print
Reactive Print. Head-32, Richo Gen 5)
Head: 64 Ricoh Gen 5 Print Head Ink Color: 8 color
quality: – HD Printable width: 72″
Max width: 130″/3.3 metre (working area). Capacity: woven-3000 yds/day Knit – 600-
Color: 8 (Cyan, Magenta, Yellow. Black, 800 kg/day
Red, Orange, Blue, Grey) Machine 2: MS LARIO Brand: Italy
Production capacity: Knit:1200 kgs/day & Head: -164 Approx.- Kyocera)
Woven: 4500/ 5000 yds/day Print type: Reactive print
Machine 2: 2 Durst Alpha_190_Italy Brand Printable width: 72″
Print type: Reactive Print. Capacity:15-20 ton /day
Head: 64 Ricoh Gen 5 Print Head Ink Machine 3: MS JPK EVO For Disperse
quality: – HDI Brand: Italy
Max width: 74″/1.9 meter. Color: 8 (Cyan, Head: -32 Print type:
Magenta, Yellow, Black, Red, Orange, Blue, Reactive print Color
Grey) 8 color Printable
Production capacity: Knit:1200 kgs/day & width: 72″
Woven: 4500/5000 yds/day Capacity: woven-5000yds/day Knit – 1500
kg/day
Machine 4: MS JPK EVO for Pigment
Brand: Italy
Print type: Reactive print
Head: -32
8 color
Printable width: 72″
Production Capacity:1500 kg/day
Echotex Textile Ltd. Apex Holding Limited.
Reggiani Machine. (Italy Brand) Reggiani machine. (Italy brand)
Reactive Print. Reactive print.
Head: 32 Head:16
Maximum print width- 72-74 inches Max width:64 inches
Production capacity: 5000 yds/day
Knit Concern Group Experience Textile Ltd.
1. Reggiani Top and Reggiani Renoir. Atexco Machine
Made in Italy Reactive Print.
Reaktive Ink
Head: -32
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Color -8
Printable width: 72- 97 inches
Capacity -1500 kg /day, 1 mc, knit fabric.
6000 meters Woven 1 mc
Machine 3: Sublimation
Reggiani Compect.
Made in Italy
Head:16
Color: 8 Dispas ink
Capacity: 4000-5000 meter
Sulimation paper print
HR Textile Mills Limited. Utah Group
MS JP7 Machine (Italy Brand) Reggiani Machine. (Italy Brand)
Head: 16 ReactivePrint.
Head name: Quicera Head: 32
Production capasity:500 m/day. Maximum print width- 72-74 inches
Only woven fabric print machine. Production capacity: 5000 yds/day
(Approx)

Viyellatex Unicom
Durst alpha 190 Machine (Italy Brand) Texlink machine (China)
Pigment Print. Head: 16(Kyocera)
Head: 64 Print type: Reactive Print
Max width:74 inches Color: 8 Color
Colour. 8 Knit
Production capacity knit:1000 kg/day
Woven: 5000 yds/day (Approx).

Impact of coating chemical in digital printing

 Standard recipe for reactive
Thickener (PC-130)-3%
Urea- (8-10) %
Sodium bicarbonate- 2%
Resist salt-1%
Rest amount of water
 Parameters
Temperature- Not more than 120°C.
Speed- About 20m/min. It can be changed according to the thickness of fabric.
Pressure- (3-5)

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Packed the coated fabric with poly as soon as possible otherwise, urea can absorb
water from the environment which can destroy the printing effect.

Advantages
1. High color yield
2. Better permeability
3. Good definition
4. Better hand feel
5. Easy to wash and have excellent fastness to rubbing.
6. High quality and save ink- save money
7. Stable printing

From the above discussion, it is clear that the selection of coating chemicals is very
important for digital printing. PC-130 is one of the reactive digital printing pastes of
Zhongshanshi Ideal New Materials Company Ltd, Guangdong Province, China. This
company provides the full solutions to digital printing auxiliaries for all kinds of fabric.

Major problems and solution of digital printing

In case of dark color print, the problem
happened in the unprinted area.
This problem can be solved by following
ways-
1. Color staining problem a) Fabric shouldn`t come into close
contact with each other during loop
formation in steaming.
b) Selection suitable coating recipe.
c) Wash should be perfect so that no
excess color in the fabric.
For full coverage design this problem
normally happens. This can be minimized
by-
2.Centre to side running shade problem (a) Wash the fabric properly before
coating.
(b) Check all fabric parameters (i.e.
absorbency, fabric PH, oil etc.) before
coating.
This problem can be solved by following
way-
3. White spot a) Remove the protruding fibers from
fabric surface before coating by singeing
or enzyme.
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 b) Clean the chemical tank properly
before coating.
It`s a very common problem in textile
industry of Bangladesh. The situation can
4. Low color yield be improved by following way:
a) Singeing and mercerization for both
knit and woven fabric
b) Selection of suitable coating chemical.
For digital printing, coating chemical has
a big impact for color yield.
Most critical problem we face in digital
printing is shade variation. We print same
design but after finishing we get different
5. Shade variation problems: shade. This can be minimized by-
(a) Coating chemical needs to make
properly. Check the viscosity and PH.
(b) During streaming, washing and
finishing need to keep all parameters
same.

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