PIGMENT PRINT BINDER
[CODE NO.3714]
Of the print systems used on cotton in the textile industry, pigment printing accounts for as much as seventy percent of the total. This system requires no pre or post treatment other than drying the fabric. The color gamut is wide, and the sharpness of prints is excellent. Pigments do not react with the cotton fiber and must be adhered to the fabric with a film forming binder, which may detract from the hand of the fabric. However, advances in binder systems have made positive contributions to print performance.
Special effects are used in addition to or in combination with pigments to impart a unique look to fabrics. Some of the special effects examined in this bulletin include resist, discharge, and burnout techniques. Alternative pigment types such as thermotropic, phototropic, puff, and plastisol technologies will also be described.
A textile pigment print system includes the following parameters:
• Pigment: A pigment colorant is a colored organic substance that is not readily soluble in most common solvents and imparts coloration to textile substrates only when incorporated with an adequate binder system.
• Binder: A pigment binder is the latex polymer resin that forms a three-dimensional film on the surface of the fiber. This film contains the dispersion of textile pigment and will act to adhere the pigment to the surface of the substrate. The permanence of this film is dependent on the polymer type and the application conditions. Binder chemistry, performance, and application is covered in Technical Bulletin ISP 1008.
• Thickener: The pigment system is composed of the textile pigment dispersed in the polymerizable resin binder, which is further mixed into a synthetic thickener system, comprised of a long chain acrylic acid. The thickener enables the pigmented print paste to stay in place once it is deposited onto the fabric prior to drying. This system is applied to the textile substrate by the following means: rotary screen printing, flatbed screen printing, engraved roller printing, coating, padding, spraying, or immersion.
Coloured pigments (as well as titanium dioxide) can be fixed onto the fibre surface though they are not bound to the fibre substance either by covalent bonds or by any other bonds normally presents between dyes and fibre substance like ionic bond, hydrogen bond, Vander waals forces etc. This is achieved in pigment printing by using suitable binders, which form transparent, soft, pliable films, which trap the pigment particles between the film and the fabric surface and react with the fibre surface.
COST ESTIMATION
Plant Capacity 2 Ton/Day
Land & Building (600 sq.mt.) Rs. 90 Lac
Plant & Machinery Rs. 40 Lac
Working Capital for 2 Months Rs. 54 Lac
Total Capital Investment Rs. 1.93 Cr
Rate of Return 24%
Break Even Point 66%
INTRODUCTION
A TEXTILE PIGMENT PRINT SYSTEM INCLUDES THE FOLLOWING PARAMETERS
PROPERTIES
PIGMENT PRINTING
APPLICATION OF PIGMENT PRINTING
B.I.S. SPECIFICATION
BASICS OF PIGMENT PRINT PASTE FORMULATION
FIGURE. VISCOSITY AND FLOW
THICKENER OR CLEAR-EXTENDER PREPARATION
AUXILIARIES USED IN PIGMENT PRINTING
ADVANTAGE OF PIGMENT PRINTING
PRINTING PRINT BINDER AND ITS APPLICATION
PASTE PREPARATION PROCEDURE
TYPICALLY PIGMENT TO BINDER RATIO SHOULD BE MAINTAINED 12.5 TO
GET GOOD FASTNESS.
TO OPTIMIZE BINDER CONSUMPTION FOLLOWING METHODOLOGY IS FOLLOWED
IMPORTANT NOTE
BINDER ECONOMICS
STORAGE & SHELF LIFE
GLOBAL OVERVIEW OF TEXTILE AUXILIARY
OVERVIEW OF TEXTILE PRINTING IN BANGLADESH
PROJECTED DIGITAL AOP CLOTHING MARKET SIZE IN VALUE (USD IN BILLION)
MARKET POSITION OF APPAREL AND READYMADE GARMENTS
APPAREL EXPORT IN TWO SEGMENTS (WOVEN AND KNIT) FROM 2014 TO 2018.
EVALUATION OF APPAREL EXPORT VALUE FROM 2014 TO 2018 CALENDAR YEAR.
2018’S APPAREL EXPORT FACTS.
BANGLADESH’S APPAREL EXPORTS EARNINGS TO NON-TRADITIONAL MARKETS.
FORMULATION AND PROCESS OF PIGMENT PRINTING BINDER
FORMULATION - 1
PART A EMULSION COPOLYMER PREPARATION (50 % SOLID)
PART (B) MODIFIED UREA FORMALDEHYDE PRE-CONDENSATE PREPARATION
FINISHED BINDER (C)
PROCESS FLOWSHEET UREA-FORMALDEHYDE PRECONDENSATE
PIGMENT PRINTING BINDER
FORMULATION - 2
PROCESS FLOW DIAGRAM
COMPONENTS OF PRINTING PASTES
PIGMENT PRINTING RECIPE AND PROCESS
PIGMENT PRINTING RECIPE
PIGMENT PRINTING PROCESS
FORMULATION AND PROCESS OIL IN WATER EMULSION FOR PIGMENT PRINTING
PROCEDURE OF PREPARATION OF OIL IN WATER EMULSION THICKENER
PREPARATION OF THICKENER PASTE
1. THICKENER WITH WATER
PREPARATION OF PRINTING PASTE
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERY
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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