In recent years, China's textile printing and dyeing industry has developed rapidly, and the printing output has also increased simultaneously. At the same time, the fashion cycle is shorter and shorter, the pattern changes faster and faster, the production requirements are higher and higher, the order batch is smaller and smaller, and the pattern piracy is rampant. Although printing enterprises have introduced digital means such as printing CAD system, laser Phototypesetter, inkjet of flat screen and round screen, wax spraying screen making machine and so on to improve the processing process in the traditional printing methods, the concept that the printing and dyeing factory is a pollution factory seems to have made a deep impression on people. At the same time, the export of China's printing and dyeing products is increasingly hindered by "non trade barriers" including the environment. In terms of current technology, digital printing is the best way to solve many problems in the printing field.
1、 Technical features of digital printing machine
Compared with the traditional printing process, the printing process of the digital jet printing system has been fundamentally changed. The process flow is simplified to design, jet printing and post-treatment, eliminating the installation of tracing, film making (or screen making, engraving) and screen (or round screen), and simplifying the process of equipment debugging and sizing; The simplification of technological process eliminates the equipment such as film making machine (or screen making machine and engraving machine) and consumable materials such as film, screen and roller.
The technical features and advantages are as follows:
◎ digital printing process, what you see is what you get, and the data storage will never fade;
◎ high quality production, high precision and rich color levels; Unable to pirate;
◎ simple printing process and short production preparation time;
◎ flexible production, suitable for personalized and small batch, effectively reducing inventory;
◎ the cost has nothing to do with the output, and the economy of proofing and small batch production is good;
◎ green environmental protection, using dyes as needed, less pollution.
Comparative analysis of round screen printing, flat screen printing and digital printing.
2、 Development track of digital printing technology
Traditional printing is inseparable from the flat screen and round screen. However, the cost and time consumed in plate making can not meet the modern printing trend of small batch and multiple varieties. Therefore, digital printing without plate and pressure has been developed. Its basic principle is the same as that of inkjet printer.
Inkjet printing technology can be traced back to 1884. American C.H. Richard put water into the syringe and applied pressure. The needle will fly out of the droplet. If the direction of the droplet is controlled, an image can be formed on the paper, which is called fog ink printing. At that time, due to the problems of needle and ink, the effect was very poor. It was not until 1960 that it officially entered the practical stage. Ten years ago, inkjet technology was used for bar code processing or product serial number printing, which is called inkjet machine.
Digital jet printing is a system engineering, involving cadwww yunxiang168. COM technology, network communication technology, precision machining technology and fine chemical technology are the products of the integration of information technology and traditional technologies such as machinery, textile and chemical industry. Because digital jet printing technology involves a lot of calculation and control, it can be said that there can be no digital jet printing technology without today's high-speed computer. At present, the development of digital jet printing technology is basically synchronized with the working ability of computer, and there is still no sign of weakening in the development of computer technology. With the development of computer technology, it can be expected that the digital jet printing technology will also develop at a high speed in the future. At the same time, the manufacturing technology of nozzle also benefits from the related technology of integrated circuit, such as etching, precision assembly and so on. The continuous emergence of modern high-frequency and multi nozzle nozzles proves this.
In the 1990s, with the gradual popularization of computer technology, the continuous digital jet printing machine appeared. By 1995, it had been mature in the textile with rough patterns such as carpet and wall hanging. Zimmer company of Austria took the lead in displaying the prototype of digital jet printing for carpets, with a resolution of 9-18. It uses valve jet technology and does not use the usual nozzle; Its production speed is very fast, up to 16 / min. However, due to the large spray droplets and low resolution, it can not be used in garment fabrics.
In 1995, the on-demand inkjet digital jet printing machine appeared. At that time, the hot bubble nozzle was mainly used with a resolution of 300dpi. Later, it gradually developed to 600dpi, mainly in four colors, which can be basically applied to fabrics.
From 1999 to 2000, the digital jet printing machine with piezoelectric nozzle was exhibited in many countries, including the Netherlands, Japan, Switzerland, the United States, Italy and China Honghua company, with a resolution of 360 ~ 720dpi, 6 / h. due to the very small minimum ink jet volume of piezoelectric nozzle (up to 6P1 when textiles are used), the product pattern is relatively fine, and the color is more uniform and natural, Therefore, it is widely popular and its application scope is gradually expanded.
At present, a variety of new digital jet printing machines have emerged, mainly using piezoelectric nozzles; The highest printing speed has developed from 1 / h in 1990 and 6 / h in 2000 to 080-150 / h; The use of dyes developed from 4 colors to 6-8 colors and 2x6-8 colors; The application technology is becoming more and more mature; The functions of control software are gradually improved.
It can be seen that the development of digital jet printing technology basically changes from continuous shooting to on-demand jet, from hot bubble nozzle to piezoelectric nozzle, and from 4 colors to 6-8 colors. At present, the development of digital printing technology is showing a trend that all Heroes rise together and a hundred flowers bloom.
From basic theory to production equipment, from application technology to dye development, and even equipment, color control methods and software are under comprehensive research and development.
In the 1990s, the number of exhibitors of digital printing products in ITMA exhibition increased from one to five. In the past five years, the number of exhibitors of digital printing products in ITMA exhibition has developed rapidly. It is reported that there are as many as 23 exhibitors of digital printing in itma2003, including equipment, dyes, process technology and so on. In particular, traditional printing machine manufacturers and dye manufacturers have invested great enthusiasm. For example, stork and Zimmer have launched four models of digital printing machines respectively, and top dye and auxiliary manufacturers such as Ciba, BASF and DyStar have improved their digital printing dyes for many times. Even Taiwan's Ministry of economy signed R & D alliances with many enterprises on December 5 last year to develop "industrial wide digital inkjet printing system technology". These international enterprises have made such great efforts to develop digital printing machines, which reflects their judgment on the development direction of textile digital printing.
3、 Application of digital printing technology and advanced production mode
At present, digital printing technology can not only be applied to personalized, small batch production and proofing of printing and dyeing enterprises, but also has entered the field of batch production. In Europe, orders within 500 meters are basically taken by digital printing machines. Many new printing and dyeing enterprises that only use digital printing system have emerged, which are combined with network design, network production and network sales, and have achieved good economic benefits. It can be said that we are ushering in a new era of digital textile.
We have assisted enterprises in Hong Kong, Shenzhen, Shanghai and other places to establish many proofing workshops using digital printing, which has improved the overall economic benefits of enterprises. We have set up a number of factories in Thailand, Malaysia and China for mass production of digital printing products, all of which are profitable. Now we are entering a new economic era. Compared with the vigorous development of the textile industry in the traditional economic era of the last century, the environment of textile production has undergone significant changes
In terms of current and future development prospects, the environment for maintaining mass production of textiles has changed, especially printed textiles. The current production mode can not meet the requirements of this environmental change.
In order to survive and develop in the new environment and win in the fierce global competition, enterprises must change their product manufacturing strategy and seek to implement a new production mode to achieve the objectives of shortening product launch time, improving product quality and reducing product cost, so as to meet customers' needs for personalized customized products at a time and price acceptable to customers, Mass customization is put forward for this demand.
Mass customization production is a new enterprise production and management mode. Its goal is to produce customized products with mass benefits, which is undoubtedly the ideal production mode that the manufacturing industry yearns for. Therefore, once the concept of mass customization production is put forward, it has attracted extensive attention and become a worldwide research hotspot in recent years. It has been successfully implemented in some enterprises and is becoming the mainstream production mode of manufacturing industry in the 21st century.
Mass customization production is a process of providing customized products with the efficiency of mass production according to the special needs of each customer under the guidance of the system, from the perspective of overall optimization, by fully tapping the potential of the enterprise and with the support of standardization technology, computer technology, modern design methodology, concurrent engineering and other technologies and ideas. Mass customization production combines the advantages of low cost of mass production and the advantages of customized production to meet the personalized and diversified needs of customers, so that enterprises can adapt to the rapid changes of the market and provide the products that customers really need at the acceptable time and price. The difference between mass customization production and traditional mass production is shown in Table 4.
The goal of mass customization production is to produce customized products with mass benefits. For users, the products are customized and personalized; For manufacturing enterprises, the product is mainly formed by mass production.
The emergence and gradual maturity of digital jet printing technology has successfully solved this problem. Only a few primary colors can be used to call out tens of millions of colors, so that small samples can be provided to customers within 24 hours. It is very convenient to organize small batch or even single piece production according to customers' needs, and the designs and colors can also be arbitrary; When digital jet printing technology is further combined with information network technology, it can carry out three-dimensional simulation and customization for customers on the network, so as to realize a completely personalized business model.