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The Coming of Age for Digital Textiles
Ink Jet Printing 2015 Conference
February 4-6, 2015The Florida Hotel & Conference Center
Orlando, Florida
Industrial Printing Markets
2
Textile
Publishing Graphics
Packaging
Product Decorati
on
Tiles Additive Manufacturing
= Digital Penetration
15%-30% Digital
Growth per year
Present 2% penetration grows to >6% in 5 years
Global Textile Printing Market
ApparelApparel
IndustrialIndustrial
Interior Interior TextileTextile
38%38%
8%8%
54%54%
>30 billion m
ApparelApparel
IndustrialIndustrial
Interior Interior TextileTextile
38%38%
8%8%
54%54%
>30 billion m2 printed per year
Textile Printing
4
Printed Textile
DTF
DTG
= Digital Penetration
Direct To Fabric• Roll To Roll• Printing before Cut
&Sew• Flat and Rotary
Screen
Direct To Garment• Printing after Cut &Sew• Flat Screen Printing
The Applications are Endless….. Swimwear
Silk Accessories
Shirt & Blouses
Sportswear
Interior Textiles
Intimate Apparel
Flag & Banner
Soft Signage
Gaming
IndustrialBanners
Gaming Tables
Apparel
Swimsuits
Silk Accessorie
s
Flags
• Heimtextil – Frankfurt
• Imprinted Sportswear Show - Long Beach, CA – Direct To Garment Printing
• DomoTex – Hannover - Carpeting and flooring printing• Texworld – NYC – Brands and Designers meet Suppliers • Current News
• Businessweek• Hemisphere Magazine
2015 – Great Start
Everyone is talking about Digital Textile Printing (DTP)
“Despite its many production advantages and the substantial savings to be made in water, energy and raw materials, digital printing still has a hill to climb before seriously challenging the established rotary and flat screen processes for textiles. Nevertheless, it’s gaining ground all the time”. John Provost
“The technology requires fewer resources and enables faster production cycles,” she said, “and textile designers can also experiment more creatively and flexibly with high-quality forms and models. In addition, purchasers of home and household textiles have the possibility to respond more quickly and more individually to today’s consumer requirements.” - Heimtextil Director Ulrike Wechsung.
Heimtextil 2015 Comments
Hemispheres Magazine Jan 2015
Bob Bland, a former Tommy Hilfiger and Ralph Lauren designer, has just launched Manufacture New York, a 160,000-square-foot complex in the Sunset Park neighborhood of Brooklyn
• Self-customization promises to be a big part of what Manufacture New York provides
Current News
“You can be online anywhere in the world, design a piece, order and have this automated process produce a garment in half an hour,” Bland says
“Customers can scan themselves on a device like a Kinect [the Xbox motion sensor]. Then we take the measurements.”
BusinessWeek – Jan 2015
• Perfecting The Science of the Shirt
• Burberry• L.L. Bean• Eddie Bauer• H&M, • Zara
More designs, shorter runs, faster delivery
Current News
• Textile World Magazine – Jan-Feb 2015
• Vapor Apparel To Open Cut-And-Sew Facility• North Charleston, S.C. based Vapor Apparel has announced it will
open a 300,000-square-foot cut-and-sew facility in Union, S.C. The company manufactures performance apparel and offers sublimation print-on-demand services
Current News
• Printing is a huge industry that is dominated by analog processes• Digital printing is growing at high rates • Cost-To-Print And Profitability Gaps are closing
• World production of printed textiles amounted to around
31 billion square meters in 2014, Provost said, and of this production, around 65% were rotary screen printed fabrics and 25% flat screen. With a variety of other different processes carried
out, digital printing had just an estimated 2% share of the
overall market, amounting to around 600 million square meters
Industrial Printing Transformation
11
• What drives digital printing?• Variable Data• Sampling • Short runs – short lead times• Customization
• What limits digital penetration?• Expertise
• Digital Work Flows, Color management, spot vs. process color• Equipment availability for production printing speeds• Cost to print versus analog
All printing should be Digital!
12
Guttenberg Press ~1439 AD
• Inkjet technology has advanced, but• 4-6 year cycles for Piezo Inkjet
• (Moore’s law for information technology is doubling every 1.5 years)
• Software, color management and digital workflows are now understood and working
• Training and knowledge improvements
• Production level printers have arrived…
Inkjet Technology Progression
13
Digital Publishing Presses
14
Océ JetStream®
Hewlett Packard
Ricoh Infoprint 5000 FujiFilm Jet Press
Offset Replacement
Digital Packaging Presses
15
EFI Jetrion Domino
DurstKonica KM1
Flexographic Replacement
High Speed Digital Textile Printers
16
ITMA Fall 2012
Screen-print Replacement
TEXTILE INKJET INK TECHNOLOGY
Ink and Fabric
• It has been a challenge to get formulations to jet well with good characteristics on the substrates
• Inkjet ink formulations now meet the challenges:• Jetting reliability• Color Consistency• End Use Characteristics
• Formulations have been optimized• Inkjet ink costs are high compared to screen
• High Purity requirements• Shelf Life• Coverage
Ink Technology
19
Cyan
Light Cyan
Magenta
Light Magenta
Black
Gray
Yellow
Orange
Blue
Red
End Use Properties
• Wash Fastness• Acid
Perspiration• Alkali• Light Fastness• Dry Crock• Wet Crock• Chlorine
Traditional vs. Digital Textile Printing
Acid Dye10% Reactive
Dye28%
Pigment2%
DS Trans-fer
52%
DS Direct8%
Digital Textile PrintingAcid Dye
3% Reactive Dye26%
Pigment51%
DS Trans-fer5%
DS Direct15%
Traditional Textile Printing
Digital Textile Ink Manufacturers
Imaging Colorants
TEXTILE PRINTING COSTSAnalog – Digital Crossover
23
• Cost Of Printing (COP) is limiting expansion of digital printing into conventional analog printing markets
• Cost Of Printing• Printer, Labor, Media, Ink, Facility, Energy, etc.
• Ink is most of the COP• Colorant is a small proportion of inkjet ink
• i.e., textile pigment ink has 4%-7% colorant• Inkjet Ink is manufactured in large batches
• Shelf life 6-24 months• Inventory and shipping costs are high
Present Situation
24
Typical Production Cost Curve
25
50 250
450
650
850
1050
1250
1450
1650
1850
2050
2250
2450
2650
2850
3050
3250
3450
3650
3850
4050
4250
4450
4650
4850
$0.00
$1.00
$2.00
$3.00
$4.00
$5.00
$6.00
$7.00
Analog vs. Digital
Screen 2012 Digital 2012
Square Meters
$/s
qm
Digital vs. Rotary Screen ComparisonSPG Prints Published Data
26
Digital Consumption100 gr/m2
Digital Consumption150 gr/m2
Run Length Cost Crossover
27
50 500
950
1400
1850
2300
2750
3200
3650
4100
4550
5000
$0.00
$1.00
$2.00
$3.00
$4.00
$5.00
$6.00
$7.00
Screen vs. Digital 2002
Screen 2002
Digital 2002
Square Meters
$/sq
m
50 500
950
1400
1850
2300
2750
3200
3650
4100
4550
5000
$0.00
$1.00
$2.00
$3.00
$4.00
$5.00
$6.00
$7.00
Screen vs. Digital 2012
Screen 2012
Digital 2012
Square Meters
$/sq
m
50 500
950
1400
1850
2300
2750
3200
3650
4100
4550
5000
$0.00
$1.00
$2.00
$3.00
$4.00
$5.00
$6.00
$7.00
Screen vs. Digital
Screen 2012
Digital 2012
DISC
Square Meters
$/sq
m
Digital Ink $ DownScreen Ink $ UpScreens $ Down
DIGITAL TEXTILE PRINTING OPPORTUNITY
28
Potential
29
Printed Textile Market sqm/yr 25,000,000,000 30,000,000,000 Each 0.1% market penetration 0.10% 25,000,000 30,000,000
liters 437,500 525,000
Each 0.1% Penetration = 500,000 liters digital inkCost/
L $ 30
$ 40
$ 50
$ 60
$ 70
$ 80
0.5% $ 65,625,000 $ 87,500,000 $ 109,375,000 $ 131,250,000 $ 153,125,000 $ 175,000,000 1.0% $ 131,250,000 $ 175,000,000 $ 218,750,000 $ 262,500,000 $ 306,250,000 $ 350,000,000 1.5% $ 196,875,000 $ 262,500,000 $ 328,125,000 $ 393,750,000 $ 459,375,000 $ 525,000,000 2.0% $ 262,500,000 $ 350,000,000 $ 437,500,000 $ 525,000,000 $ 612,500,000 $ 700,000,000 2.5% $ 328,125,000 $ 437,500,000 $ 546,875,000 $ 656,250,000 $ 765,625,000 $ 875,000,000 3.0% $ 393,750,000 $ 525,000,000 $ 656,250,000 $ 787,500,000 $ 918,750,000 $ 1,050,000,000
3.5% $ 459,375,000 $ 612,500,000 $ 765,625,000 $ 918,750,000 $ 1,071,875,000 $ 1,225,000,000
4.0% $ 525,000,000 $ 700,000,000 $ 875,000,000 $ 1,050,000,000 $ 1,225,000,000 $ 1,400,000,000
4.5% $ 590,625,000 $ 787,500,000 $ 984,375,000 $ 1,181,250,000 $ 1,378,125,000 $ 1,575,000,000
5.0% $ 656,250,000 $ 875,000,000 $ 1,093,750,000 $ 1,312,500,000 $ 1,531,250,000 $ 1,750,000,000
5.5% $ 721,875,000 $ 962,500,000 $ 1,203,125,000 $ 1,443,750,000 $ 1,684,375,000 $ 1,925,000,000 6.0% $ 787,500,000 $ 1,050,000,000 $ 1,312,500,000 $ 1,575,000,000 $ 1,837,500,000 $ 2,100,000,000 6.5% $ 853,125,000 $ 1,137,500,000 $ 1,421,875,000 $ 1,706,250,000 $ 1,990,625,000 $ 2,275,000,000 7.0% $ 918,750,000 $ 1,225,000,000 $ 1,531,250,000 $ 1,837,500,000 $ 2,143,750,000 $ 2,450,000,000
6% Penetration > $1B Ink
"Textile Printing Production to Reach 32 Billion Square Meters by 2015” (ITS, PIRA, Infotrends)
30
Run Length Analysis
100
60011
0016
0021
0026
0031
0036
0041
0046
0051
0056
0061
0066
0071
0076
000
20
40
60
80
100 Digital
Linear Meters
100
600
1100
1600
2100
2600
3100
3600
4100
4600
5100
5600
6100
6600
7100
7600
020406080
100
Screen
Linear Meters
100
70013
0019
0025
0031
0037
0043
0049
0055
0061
0067
0073
0079
000
20406080
100120
Normalized Run Lengths Comparison
ScreenDigital
Linear Meters
100
90017
0025
0033
0041
0049
0057
0065
0073
000
20406080
100120
Normalized Run Length Comparison
ScreenDISC
Linear Meters
Axis Title
3200k Liters
25000k Liters
The market wants to print here…but can’t at present
Exponential Growth
Relative Ink Volumes
Digital = 3.5M LScreen = 280M L
31
Profitably Gap
32
Screen
The gap between the low volumes of digital and the high volumes of rotary screen printing shows the
economic potential
Digital Opportunity
INKJET PRINTHEAD TECHNOLOGY
RC1536Performance SPT RC1536
RC1536Print width 108.3mm
number of nozzles 1536
Resolution 360
Grayscale 8 levels
Drop Volume 17-100pl
Dot Frequency 10.4kHz (7drop)
Productivity/nozzle [kHz*pl] 1040
Productivity/head [ml/min] 95.8
number of heads/Bar*1 7
Max Discharge/Bar*2
[g/2@25m/min]48.8
(360dpi*634dpi)
*1: 1Bar=700mm
*2: Specific gravity=1.38
Circulation +
Isolated Channel Technology
Konica Minolta's next-generation flagship model, “KM1800i,” is a newly-developed high-performance multi-nozzle inkjet printhead furnished with 1776 nozzles and capable of a print width of 75 mm. The product features include an independent drive method that enables simultaneous jetting from all nozzles, 1776 nozzles with a high density of 600 npi and is ideal for commercial printing applications that require high-speed printing with the high image quality realized by the single-pass method. Major Features
Multi-nozzle structure with 1776 nozzles and a 600 npi high-density printhead
All-nozzle independent drive system, maximum drive frequency: 84 kHz
Stable discharge performance that realizes high image quality during high-speed printing
Grey scale performance with a maximum of 8 gradations
3.5 pl small droplets, UV-ink compatible
Next-generation Inkjet Printhead “KM1800i”
G51280 nozzles
• MEMS Drop Ejector• Drop-on-demand• Silicon MEMS construction with sputtered PZT film actuator • High print speeds: >100 kHz jetting frequencies• Native drop volumes (1…5 pL)• Multi-pulse capable for larger drop volumes (up to 6x )• VersaDrop Gray Scale• Excellent jet straightness
• Ink Compatibility• Wide ink latitude (material, temperature, viscosity range)• Continuous ink recirculation• Robust non-wetting coating• Aqueous (dye and pigment), UV, aqueous-UV, latex, and solvent-based inks
• Scalable Architecture• High resolution: 1200 nozzles per inch• Unique matrix nozzle pattern for ease of stitching• Small footprint and modular design• Field replaceable
SAMBA™ Inkjet Printhead Technology
MultiDrop – Gray Scale Technology
39
• MultiDrop Technology• Gray Scale
Nozzle Plate Materials Nickel Stainless Steel Polyimide Silicon
Nozzle Holes Etching Laser Drilling Punching Electroform MEMs
Nozzle Plate Coatings Wetting – no coating Non-Wetting Coating
Nozzle Plate Technology
Key benefits: Improves initial priming Enables fast jet recovery Prevents settling of heavily pigmented inks Improves open time of fast drying inks Uniform Temperature Control
Continuous Circulation
41
Continuous Ink Flow
MORE PRINTERS
Durst Kappa 320 at Heimtextil
Mutoh 1638WXMutoh RJ-900X
MS LaRIO
Reggiani ReNOIR
Standard Mid-Range High Speed Extreme Speed
Mimaki JV-33 Mimaki TX-500 MS JP-6
Printing Equipment
ArioJet
• Direct To Garment• Production Digital
Printing• Replaces a screen-print
station
Paradigm Production Digital DTG
• Direct To Garment• Production Digital
Printing• Replaces a screen-print
station
• Now, with the introduction of single pass machines, digital printing is capable of operating at speeds faster than rotary printers.
• MS in Italy has already introduced the LaRio single pass machine
• Kyocera Printheads
Single Pass Digital Printers
35 - 75 liners meters per minute63 sqm per minute3500 sqm per hour
Rotary Screen Speeds
• SPG Prints announced Pike, a new single pass digital textile print• 75 meters per minute
• Samba printheads on the system are configured in a single-pass array called Archer
• throw distance• nozzle redundancy
• Targeted at rotary screen printers printing between 3 million and up to 10 million meters annually.
• Ink Consumption: 65k liters to 210k liters
Digital Textile Printing Success (US)
49
Opportunities from Growth Barriers
• Printers (of course)
• Auxiliary Equipment• Dryers• Calendars• Steamers • Washers• Environment Controls
• Capital Equipment Financing• Color Management• Workflow Optimization• Web To Print• Technician Training• Operator Training• Ink Production and Supply Chain
$
Grow Industrial Digital Printing
51
TextileGraphics
Packaging
Product Decoration
Tiles Additive Manufacturing
Digital Textile• Production Solutions
are INKJET• Highest Ink Volume
• All aqueous• Green Technology
Accelerating
Digital G
rowth
Dry tonerLiquid TonerOffset LithographyFlexographicHybridGravureScreenprint
• Laser• Inkjet
• Inkjet
• Laser• Inkjet
• Inkjet
Thank You
The Technology Partnership ‘TTP’Melbourn, Herts. SG8 6EE. UK
Mike RaymondTechnical Sales – Business Developmentttpmeteor, Philadelphia Office, USA
https://www.youtube.com/watch?v=FxuXP0BRBxM