garmentprinting-120202065211-phpapp02

8/12/2019 garmentprinting-120202065211-phpapp02

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AN

INTERNSHIP REPORTON

Thrupti Designers(GARMENT PRINTERS)

By,

Rajesh. K

Siva Jagadish Kumar.MTejas. Kulkarni


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Company Profile

Thrupti Designers - renowned garment printer in

Bangalore.

Started in the year of 2004.

Situated at Begur Road, Bangalore as a 2ndunit ofthis organization.

It is a first printing unit to get certified with GOTS, &

Organic Exchange certification in Bangalore. Production capacity 30,000 pieces/day of single

color.


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Customer List

Shahi Exports Pvt Ltd (Wovens & Knits Divisions)

Integra Apparels & Textiles Pvt Ltd

Natural Textiles Pvt Ltd

LVK Baby Wear Pvt Ltd Sunitha Impex Pvt Ltd

Graffiti Exports

Mahalakshmi Inc

My Choice Garments Imperial Garments (Hyderabad)

Gokaldas Exports

BLR Knits Pvt Ltd


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Infrastructure

Equipped with following machineries for

production and sampling.

Type No. of Units.

Big Tables (25 meters of each) 02

Pallet Printing Machines 12 ( 10 of 8 colours & 2 of 12 colours)

Curing Machine 01

Digital Pneumatic Fusing Machine 10

Colour Matching Cabinet (Paramount) 01

Air Compressor 01

Diesel Generator 01


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Organisation Structure

Proprietor

HRD

Manager

HR Assistant

Production

Manager

ProductionSupervisor

PrintersGrade I

Printers

Grade II

Helpers

Designer

Exposure,

Screen Maker

Assistant

Manager

Accounts

AccountsAssistant


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SCREEN

PRINTING


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Screen Printing

A process, where ink is mechanically applied

to a substrate with the use of a screen and

squeegee.


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Colour Separation

Each colour of the design requires an

individual screen so we must separate the

design into its component colours. This is

done on the computer and each colour

separation is printed to a transparent sheet.


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4 Colour Separation

4-colour process is a more advanced separation and printing technique.

Uses 4 colours of transparent ink to produce the colours from the original

design.

The four colours, Cyan, Magenta, Yellow, and black (CMYK), are printed as

half-tones that interact with each other and the white background of theshirt to create colour and tonal values.


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Printing Mechanics

The screen is then mounted in the press and aligned so that

each colour prints in the proper location relative to the other

colours.

Ink is loaded into the screens and squeegees are installed.

As the squeegee scrapes across the screen with the ink it fills

the stencil with ink while simultaneously bending the mesh

down to transfer the ink to the shirt.


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Screen Printing


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Multi Colour Printing


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Mesh count

The mesh count is the number of threads per

inch (tpi) used to weave the mesh.

Typical mesh counts for screen printing range

from 85 tpi to 355 tpi.

The high mesh counts, have a very small

thread diameter and less open area.

Prints require more fineness should be use

finer mesh count.


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Mesh count

Glitter 2560

Flock adhesive 45125

Puff-up colors 55125

Overprint 80110

Pigment ink printing areas/lines 110175

Plastisol 125305

Pigment inks, half-tone 155255

Sublimation transfer 195305


17/50DIFFERENT TYPES OF PRINTS


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Plastisol Print

Good colour opacity ontodark garments and cleargraphic detail with, as thename suggests, a more

plasticized texture. Plastisol inks require heat

(approx. 150C) to cure theprint.

Due to excess phthalate inPVC, this is banned forChildrenswear.


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Non PVC

Relatively new breed of inkand printing with the benefits

of Plastisol but without the

main toxic components - soft

feeling print.

Suitable for kids wear.


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High Density Print

This is one of the recent

developments in printing which

gives thick prints on the surface

of garments.

Achieved by either giving more

number of coats or by using

thickener indirect films used for

making the screens.


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Suedo Ink Print

Suede is a milky

coloured additive that is

added to Plastisol. With

suede additive you canmake any colour of

Plastisol have suede

feel.

Generally 50% suedeadditive to your normal

Plastisol.


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Discharge Print

Used to print lighter

colours onto dark

background fabrics, they

work by removing thedye already present in

the garment.

This gives a much softer

texture


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Sticker Print

This is ready to transferprint.

The plastisol print isalready printed on paperand will be transfered onto garment in the fusingprocess.

The main advantage ofthis method is lessexpensive.


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Pigment Print

These penetrate the

fabric more than the

Plastisole inks and

create a much softerfeel.

Also useful for larger

area prints where

texture is important.


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Glitter Print

Metallic flakes are

suspended in the ink

base to create this

sparkle effect. Usually available in gold

or silver but can be

mixed to make most

colours.


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Metallic Print

Gives metallic look.

Similar to glitter, but

smaller particles

suspended in the ink.

Smooth in texture whencompared to glitter.


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Foil Print

This printing method is

based on the use of

metallic foil paper of

aluminium or copperone.

The print fixation

method is similar to

transfer printing. Thisprint method is popular

amongst youngsters.


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Distressed/ Khadi print

It consists of titanium

dioxide with other

auxiliaries.

The important factor in

printing of this is right

combination of titanium

dioxide and proper

choice of binder.


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Puff Print

An additive to Plastisolinks which raises the printoff the garment, creatinga 3D feel.

In this method when thepaste is printed and driesit look like normalprinting garments but

once it is cured the printsgets raised from thesurface of fabric.


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Cavier Bead Print

A glue is printed in the

shape of the design, to

which small plastic

beads are then applied.

works well with solid

block areas creating an

interesting tactile

surface.


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Silicone Print

To counter inferior washand weather durability,poor hand feel of someprints like plastisol

printing mills triedsilicone inks because oftheir good washingdurability, hand feel,

elongation propertiesand environmentalfriendliness.


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Flock Print

This process involvesprinting of glue on thefabric first, applying thefiber flock on the gel

printed by keeping thefabric on special table(electro staticallycharged).

It requires a little hightime for curing thannormal prints. 120seconds at 160C will besufficient for curing.


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Organic Print

Organic print rangecovers the natural dyes,and the other pigmentdyes which lies under

the specifications madeby G.O.T.S.

For Printing OrganicDyes the company/

manufacturer shouldget the certificationfrom G.O.T.S.


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SamplingProcess


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MACHINES

USED IN

PRINTING

6- COLOUR SCREEN

PRINTING


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CAROUSAL PRINTING

MACHINE

These machines will beavailable both in automatic

and semi automatic

machines and with 4, 6, 8,

10 & 12 multi colour

models. The double springmodel gives the customers

a maintenance free

performance of the

machine. Electric heat

panels included in the

machine.


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DIGITAL FUSING

Used As Heat Transfer Press,Designs To Be Transfered ToThe Garments / Fabrics /

Leathers/ Rexin /Nylon /Polyprpelene/ Bags & etc.

Can be used for fusing likeplastisol priniting, khadi,

pigment & etc. Can Be Used As Flat Bed Fusing

Machine For Collar And CuffFusing

Platen Size Can Be IncreasedUp to 20" X 30".


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ELECTRIC CURING

MACHINE

Electric curing used for

fixing the printing paste on

to the printed fabric.

This is the alternate

method for Line Drying.So that instead of waiting

for 3-5 hours for line

drying, the electric curing

process can be completed

in few minutes.


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COLOUR MATCHING

CABINET(SPECTRA VISION) Artificial Daylight

Fluorescent Lamps (D-65) Tungsten Filament Lamps

(Inc A Lamps)

Cool White FluorescentLamp (CWF)

Triphosphor Fluorescent

Lamp (TL-84) Ultra-Violet Black Lamp


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COST, M.O.Q of the Various Types of

PrintsPrint Type Cost of Print in

Rs.

M.O.Q Curing / Fusing Suitability for

Children

Durability

Rating

Sticker Print 1 2500 Fusing No 1.5

Plastisole Print 1.5 1000 Fusing No 2.5

Pigment Print 2 1000 Curing Yes 3

Non-Pvc Print 2.5 1000 Curing Yes 2.5

Distressed (Kadi)Print

2.5 1000 Curing Yes 2.5

Foil Print 3.5 500 Fusing Yes 2

Gel Print 3 1000 Curing Yes 3

Discharge Print 3 500 Curing Yes 3

Glitter Print 3.5 1000 Curing Yes 2

Sugar Print 5 1000 Curing No 2

Metallic Print 4 1000 Curing No 2

High Density Print

(6 Coats)

5 500 Curing Yes 3.5

Puff Print 3.5 1000 Curing Yes 3

Flock Print 5 1000 Curing Yes 2.5

Silicone Print 8 500 Curing Yes 4.5

Organic Print 6.5 1000 Curing Yes 3

Bits Printing 4 2000 Fusing No 2

COST M O Q Analysis for Various


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COST, M.O.Q Analysis for Various

Types of Prints


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COST & M.O.Q Analysis for Various

Types of Prints


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Printing Defects

Improper alignment: Causes: Improper setting of two different

screens of different colour

Colour spread: Causes: Less viscosity of print paste is less. Base

fabric not fixed properly.

Improper mixing of print paste: Causes: As the name itself implies the print

paste ingredients are not mixed properly leadingto some yellowing or stain marks on print.

Scrimps: Causes: The print is done on folded fabric.


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Printing Defects

Smear

Causes: Printing is done on seams which will be of

different thickness leading in spreading and blurring.

Difference in texture Causes: Improper fusing

Improper colour matching

Causes: If printed colour is not matching with standard.


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Printing Defects

Stick in Causes: Some dust and lint which get chock in screen holes

leads in improper design.

Doubling or blurring Causes: Improper fixing of base fabric or screen.

Lint or thread marks Causes: Any loose threads come in print area will lead to

thread marks on print. Colour stains

Causes: Improper handling of material.


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Printing Defects

Glue streak Causes: The gum which used to stick garment and/or the gel which is

printed on fabric (for foil, flock etc.) strikes out of fabric through backside.

Low sharpness Causes: Improper mesh selection , damaged screen.

Coloured/White spots Causes: Improper screen preparation.

Distorted print Causes: printing of second coat before drying 1stcoat.

In general 1-3% of defective pieces in bulk order is allowed,

but since the defect occurrence is very less its always less

than the limit


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References

Web References http://www.gfxsp.com/faq_sp.html

http://en.wikipedia.org/wiki/Screen_printing

http://www.cheranfusing.com

http://www.dowcorning.com/screenprinting

Book Reference

Screen PrintingA Contemporary Approach, Samuel B. Hoff, DelmarPublishers, 59.

Industrial References

Mr. Hanumanth Rao (ManagerProduction, Thrupti Designers).

Mr. Upendra Kant (ManagerAdministration, Thrupti Designers).

Mr. Praveen. S.P. (Sr. Merchant, Shahi Exports Pvt. Ltd, Unit-12)


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Thank You!!!

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