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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



ZIMMER AUSTRIASince 1874 in textile printing industry. Since more than 40 years digital!



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



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.



FLOOR COVERINGS

TEXTILE PRINTING

Business segments at ZIMMER AUSTRIA Kufstein

SPECIALITIESDIGITALFUNCTIONALIZATION

NARROWFABRICS



Digital Printing Systems | CHROMOJET & COLARIS

COLARIS.INKJET PRINTINGCHROMOJET.VALVEJET PRINTING



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



Direct Inkjet PrintingThe Technology that is replacing

established Production Methods?!



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



Case Study #1Jacquard Weaving of Carpets



Case Study #1

Jacquard Weaving of CarpetsBring Color on a Substrate

picture: www.woolcarpets.store

woven carpet rugs

http://www.woolcarpets.store/



Case Study #1


picture: www.vandewiele.be

Jacquard weaving loom

http://www.vandewiele.be/



Case Study #1



Jacquard weaving loom with colored yarn coils




Case Study #1



warp and weft threads




Case Study #1

Jacquard Weaving of Carpets➔ Digital Printed!Bring Color on a Substrate

customer show room printed with COLARIS and disperse inks



Case Study #1


print imitates Jacquard structure penetration is key



Case Study #1


designs with thousands of colors and fine gradations



Case Study #1


COLARIS printing linefor woven PES carpets



Case Study #1


COLARIS digital inkjet printer in 4.2m (13ft) width



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




Case Study #2Needlepunching of Nonwovens



Case Study #2

Needlepunching of NonwovensBring Color on a Substrate

picture: www.hunterdouglasarchitectural.eu

nonwovens as style and acousticceiling elements

http://www.hunterdouglasarchitectural.eu/



Case Study #2


picture: www. acoufelt.com

nonwovens as style and acousticwall & ceiling panels




Case Study #2


picture: www.hunterdouglasarchitectural.euwww. acoufelt.com

solid color palettes





Case Study #2


picture: www. andritz.com

needlepunch production line needleloom




Case Study #2


picture: www. andritz.com

for coloration pre-dyed staple fibers are used, either of one color or mixing more colors for effects




Case Study #2

Needlepunching of Nonwovens➔ Digital Printed!Bring Color on a Substrate

customer acoustic panels (raw material)



Case Study #2


printed with COLARIS and pigment inks



Case Study #2


various constructions and thicknessesany kind of color and shade is possible



Case Study #2


3D effects



Case Study #2


imitation of other materials (concrete, wood, metal etc.)



Case Study #2


imitation of multi-color needlepunch no limits in level of detail (scale in mm)



Case Study #2


COLARIS line for roll-to-roll printing on nonwovens, up to 5.2m (17ft) width

COLARIS for printing on piece goods (panels & tiles)



Case Study #2



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)



Case Study #3Indigo Dyeing of Denim



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

http://www.pinterest.com/



Case Study #3


picture: www.pinterest.com

indigo blue is used for dyeing denim fabrics, it is a vat dye (kind of a non-soluble pigment)




Case Study #3


picture: www.seu.edu.bd

washing process is key to make the look of a typical blue jeans

http://www.seu.edu.bd/



Case Study #3


picture: www.wwt.com

the downside of today‘s denim process:impressive impact on environment and humans




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



Case Study #3


COLARIS printing line for2-phase VAT printing



Case Study #3


imitating denim look with samefastness properties of conventional process



Case Study #3



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



Case Study #4Pre-/Post-Treatment of Fabrics



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



Case Study #4


Standard method for pre-/post-treatment:

Padding

picture: www.kusterstextile.com

typical pick-up ratio in a padderis 60-100% of fabrics weight




Case Study #4


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)



Case Study #4


More intelligent method of pre-/post-treatment:

Spraying

picture: www.swift-jet.com




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

http://www.researchgate.net/



Case Study #4


= + + +

RGB K C M Y

jetable fluid(either pre- or post-treatment)

consumption isequal to ink laydown!



Case Study #4


• 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!



PRE-Coating

Drying PRINTING DryingPOST-

CoatingDrying

COLARIS PRINTING with inline PRE-/POST-Coating

Drying

Case Study #4


PIGMENT PRINTING

COLARIS pigment printing line with inline pre-/post-treatment via jetable fluids



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


COLARIS circulation system for jetable fluids COLARIS temperature control system



PRE-Coating

Drying PRINTING Drying Steaming Washing Drying

CHROMOJETinline PRE-Coating

COLARIS PRINTING

Steaming Washing Drying

REACTIVE PRINTING

Case Study #4


reactive towel printing line with COLARIS (4) and CHROMOJET inline pre-treatment system (3)



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


CHROMOJET printing module for jetting pre-treatment pastes



Case Study #4



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



(1) breathable membrane(2) antibacterial(3) soil release finish(4) pattern printing(5) photochromic effects

The future of textiles:

Digital Functionalization!

Case Study #4




And we are not that far away!

Case Study #4


picture: www.pireta.co.uk

smart textiles, printed with CHROMOJET technology

http://www.pireta.co.uk/



Case Study #4


picture: www.pireta.co.uk

smart textilesprinted with CHROMOJET technology

http://www.pireta.co.uk/



ZIMMER AUSTRIAMarco Rueckl

Sales Manager | ZIMMER AUSTRIA Kufstein+43 664 886 899 64 | [email protected]

CREATING SUCCESS STORIES40 YEARS OF DIGITAL PRINTING

direct inkjet printing - map your show › mys_shared › pru19... · direct inkjet printing the...

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