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Colaris Digital Textile Printing ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS COLARIS DIGITAL TEXTILE PRINTING HOME TEXTILES APPAREL DECORATION AUTOMOTIVE FLAGS & BANNERS www.zimmer-austria.com 2020.01.15 page 1 CONTENT 1. INNOVATION IS IN OUR DNA 1.1. HISTORIC MILESTONES 3 2. INK CLASSES 2.1. TYPES | PRODUCTS | PROCESS | REQUIREMENTS 4 2.2. TYPES | PRODUCTS | PROCESS | REQUIREMENTS 5 3. PRINT TECHNOLOGY 3.1. PROCESSING DIAGRAM 6 3.2. PROCESS EQUIPMENT 7 4. REACTIVE PRINTING 4.1. GENERAL INFORMATION 8 4.2. EXAMPLE: TERRY TOWEL PRINT PRODUCTION 9 5. ACID PRINTING 5.1. GENERAL INFORMATION 10 5.2. EXAMPLE: UPHOLSTERY PRINT LINE 11 6. DISPERSE / SUBLIMATION PRINTING 6.1. GENERAL INFORMATION 12 6.2. EXAMPLE: PES BLANKET PRINT LINE 13 7. VAT INDANTHRENE® PRINTING 7.1. GENERAL INFORMATION 14 7.2. APPLICATION DIVERSITY 15 8. PIGMENT PRINTING 8.1. GENERAL INFORMATION 16 8.2. APPLICATION DIVERSITY 17 9. CATIONIC PRINTING 9.1. GENERAL INFORMATION 18 10. COLARIS - CHARACTERISTICS AND FEATURES 10.1. COLARIS MODELS 19 11. COLARIS FEATURES AND COMPONENTS 11.1. INTEGRATED MACHINE COMPONENTS 20 11.2. INTEGRATED MACHINE COMPONENTS 21 12. PROCESS EQUIPMENT 12.1. INLINE COMPONENTS 22 12.2. OFFLINE COMPONENTS 23 13. PRINT HEAD 13.1. TECHNOLOGY 24 13.2. RECONDITION CENTER 25 14. ZIMMER TECHNOLOGY & APPLICATION CENTER 14.1. GENERAL INFORMATION 26 14.2. EQUIPMENT & FACILITIES 27 www.zimmer-austria.com 2020.01.15 page 2 1. INNOVATION IS IN OUR DNA 1.1. HISTORIC MILESTONES Vertical Duplex blanket printer from 1951 First commercial rotary screen printer 1958 The broad digital competence of ZIMMER AUSTRIA is based on an innovation introduced more than 4 decades ago. 1976 - ZIMMER has entered the digital age with the introduction of the Chromotronic printer concept to the carpet industry. The CHROMOJET has inherited the technology and become a mind changing milestone for the carpet industry. It turned machine made carpet manufacturing literally upside down. Both the CHROMOTRONIC and the CHROMOJET have been 8 color CHROMOTRONIC printer based on high speed electromagnetic valve technology developed by ZIMMER in the city of Kufstein in Austria. Digital textile printing started with the CHROMOTEX printers in the early days of this Millennium. CHROMOTEX was based on continuous Inkjet technology. The first real commercial printers have entered the market from 2008 onwards and are sold under the brand name COLARIS. Today COLARIS is best known for economic printing on medium to heavy weight substrates, including upholstery, velour, plush, terry, blanket, needle felt and even heavy weight tufted or woven carpet substrate. CHROMOJET carpet printer at M2Carpet CHROMOTEX system, 2001 COLARIS line, 2008 www.zimmer-austria.com 2020.01.15 page 3 2. INK CLASSES 2.1. TYPES | PRODUCTS | PROCESS | REQUIREMENTS INK CLASS USED ON END PRODUCTS PROCESS REQUIREMENTS REACTIVE cellulosic, fashion, inkjet pre-treatment protein based, home furnishing, printing-drying and polyamide fibers decorative fabrics, steaming terry towels post print washing drying ACID AND protein based, fashion & lingerie, inkjet pre-treatment METAL COMPLEX and polyamide fibers sports & swimwear, printing-steaming-drying tents, post print washing flag & banners, drying technical textiles, military applications DISPERSE PES fibers fashion, inkjet pre-treatment DIRECT home furnishing, printing-drying-thermal SUBLIMATION flags & banners, fixation awnings & parasols, reductive washing camping & outdoor, drying automotive, technical textiles VAT cellulosic based fibers high performance inkjet pre-treatment INDANTHRENE® home furnishing, printing-drying workwear, inline padding-steaming- uniforms, washing-drying military applications PIGMENT any kind of fibers fashion, inkjet pre-treatment home textiles, printing-drying and outdoor fabrics, thermal fixation awnings & parasols, advertising fabrics, technical textiles, military applications CATIONIC acrylic fibers, outdoor fabrics, inkjet pre-treatment cationic PES, blankets, printing-drying- and aramid fibers workwear, steaming-washing- military applications drying www.zimmer-austria.com 2020.01.15 page 4 2. INK CLASSES 2.2. TYPES | PRODUCTS | PROCESS | REQUIREMENTS COLOR FASTNESS APPLICATIONS light fastness + wash fastness +++ crock fastness ++ chlorine fastness + brilliancy ++ light fastness + wash fastness ++ crock fastness ++ chlorine fastness + brilliancy +++ light fastness + wash fastness ++ crock fastness ++ chlorine fastness + brilliancy +++ light fastness +++ wash fastness +++ crock fastness ++ chlorine fastness ++ brilliancy ++ light fastness +++ wash fastness + crock fastness + chlorine fastness ++ brilliancy ++ light fastness +++ wash fastness ++ crock fastness ++ chlorine fastness + brilliancy ++ www.zimmer-austria.com 2020.01.15 page 5 3. PRINT TECHNOLOGY 3.1. PROCESSING DIAGRAM According to the substrate to be printed and the ink family used, the print technology differentiates in its process steps. Various options and equipment solutions are available to cover all different needs. RFP fabric (Ready for print) 1 Offline pre-treatment 2 Inline DIGITAL Inline pre-treatment PRINTING drying 3 Inline Offline Offline steam fixation steam fixation hot air fixation 4 Post-print washing recommended for any process 5 Drying / Finishing www.zimmer-austria.com 2020.01.15 page 6 3. PRINT TECHNOLOGY 3.2. PROCESS EQUIPMENT For a good color yield and sharp print results the fabric needs inkjet pre-treatment. 1 Offline pre-treatment Direct print-dry-fixation keeps energy consumption low. PIGMENT printing represents this simple and ecologic print process. No post-print washing required, thus saving a great amount of water and energy. 2 Digital printing With REACTIVE and ACID printing, fixation is done in steam condition. A good portion of unfixed dyes remains in the substrate. Post-print washing is mandatory. Washing process consumes a substantial amount of water, detergents and additives. 2 Digital printing Additional drying pass required. Washing and drying have an adverse impact on process costs and on the ecology of print production. Nevertheless, haptics and brillancy are benefits of reactive and acid, compared to 3 Offline steam fixation pigment prints. 4 Post-print washing 5 Drying / Finishing www.zimmer-austria.com 2020.01.15 page 7 4. REACTIVE PRINTING 4.1. GENERAL INFORMATION REACTIVE PRINT LINE REACTIVE ink is used on fabric made of cellulosic fibers such as cotton, linen, viscose, etc. It may also be used for printing on nylon substrates. REACTIVE printing requires an alkaline environment for dye fixation. This is provided through inkjet preparation of the substrate. Dependent on substrate, the preparation can be done in an inline or an offline process. Magnoroll MR 6 stenter Dye fixation is achieved through a steaming process. As per requirement of the substrate, steaming can be done inline or offline. Dry heat fixation would be possible too. MODUS loop steamer Unfixed dyes and pre-treatment chemicals need to be removed by a post-print washing process. REACTIVE prints are known for a good wash fastness, fine haptics and brilliant colors, achieved by thorough clean- sing in a post-print washing process. Typical applications are fashion fabrics, cotton and cotton/ viscose blended bed sheets, terry towels and other cellulosic based substrates. www.zimmer-austria.com 2020.01.15 page 8 For more 4. REACTIVE PRINTING details: TOWEL 4.2. EXAMPLE: TERRY TOWEL PRINT PRODUCTION leaflet TERRY TOWEL PRINT LINE Typical REACTIVE print applications are terry towels or bathrobes. Such items are more and more fashionable and are considered as a personal statement. Fancy, multi-color designs are economical with the digital print process only. A typical terry towel layout is an all-inline print process, followed by offline washing. Terry and velour need a perfect penetration control. Pre-treatment printing line at C4CC, NLD Post-print washing for reactive terry towel prints is mandatory. Towel washer at C4CC, NLD Aside beach towels, the promotional market as well as the health and beauty segment are creating new demand. www.zimmer-austria.com 2020.01.15 page 9 5. ACID PRINTING 5.1. GENERAL INFORMATION Digital print line for voluminous PA substrates at S-Print BEL ACID ink is used to print polyamide fibers as well as silk and wool. An acidic environment for fixation of dyes is provided through digital inkjet preparation of the fabric. When printing polyamide pile substrate, it is recommended to raise and open the pile by pre-washing or through a steam treatment to achieve a homogeneous print result with good penetration. Pre-steamer Polyamide substrates printed as piece goods need a special sandwich washer for removal of unfixed dyes and acidic chemicals. Sandwich washer ACID prints are known for good fastness properties. Nevertheless, if special requirements on wash or light fastness are required, pre-metallized inks are available. Such inks are good for improved light and chlorine fastness. www.zimmer-austria.com 2020.01.15 page 10 For more 5. ACID PRINTING details: CARPET 5.2. EXAMPLE: UPHOLSTERY PRINT LINE leaflet UPHOLSTERY ACID PRINT LINE ACID print lines are more complex than a simple print and dry process. Most important criteria for velour or loop fabric is penetration and sharpness of the print. Typical ACID print applications are upholstery and fabrics for public transport vehicles or transport fabrics made from wool or polyamide, or a blend of these fibers. “Wet in Wet” print process, followed by inline steaming, reduces energy consumption to a minimum, as steaming time is reduced by more than
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