TRANSFER PRINTING

Transfer printing in textile means the sublimation of dyes from a colored design on
paper at high temperature followed by absorption of the dye vapors by synthetic fibres
in the fabric.

The process of transfer printing consists of transferring the colored design from pre-
printed paper to fabric under the action of controlled condition of temperature, time and
pressure.

Transfer printing was first patented in France in 1958. But it came in market
commercially as heat transfer printing in 1968.

Both woven and knitted fabrics can be transfer printed but the major use of this method
is on knitted items. This printing process may either be continuous or batch wise by
which T-shirts, sweaters or other partially or fully assembled garments can be printed.

Conditions required for Transfer printing: The following conditions are required for
the process:

1. A range of miscible dyes that sublime at high temperature preferably in a

narrower range and have substantivity for synthetic fibres to be printed but little
or no affinity for the pre-printed paper.
2. The molecular weight of these dyes falls in the range 230 to 370 which can
further be narrowed to 250 to 340.
3. The synthetic fabrics should have necessary physical, chemical and
thermoplastic properties to withstand the high processing temperature. The fabric
must be dimensionally stable up to a temperature of 2200C during the transfer
period to ensure good pattern definition.
4. The dye should readily sublime at around 2000C temperature.

Types of Transfer printing: Four (4) types of transfer printing-

1. Sublimation or dry or vapour phase printing(Heat transfer printing)

2. Wet or migration transfer printing.
3. Film release transfer printing.
4. Melt transfer printing.

1. Sublimation or dry or vapour phase printing(Heat transfer printing):

 This is the most widely used transfer printing process, which became
commercially available in 1929-30 in England.
 This is a physical process where a design is replaced from one material to a
textile substrate.
Two step required for printing-

1st Step: The pattern/design is printed on a special paper by paper printing or modified
textile printing machinery using printing paste/ink(containing volatile disperse dyes and
suitable thickener/ binders). This printed paper is then dried at low temperature.

2nd step: The transfer of the printed design/ pattern from the paper to the textile
substrate is effected by forming a sandwich of printed paper and textile fabric followed
by exposure to heat and pressure at a time in a suitable machine specially developed
for this purpose(transfer printing machine).

The sublimed dye vapour diffuses into the gap between paper and fabric to be
condensed on to the fabric surface and subsequently diffuses into interior of the fibres.

In this transfer printing –

 Heat requirement varies from 1500-2300C practically 1700-2100C.

 Time requirement is 15-20sec.
 Only non-ionic volatile dyes are suitable.
 Polyester and cellulose triacetate are suitable to print.

Quality of print paper for transfer printing:

Any paper can be used after giving the surface coat and glazing. This is done because
cellulosic paper material may absorb some dye and may be stained. So this gelatin
coating makes the paper impermeable.

The requirements of quality of transfer printing paper are mentioned below:

1. Paper weighing from 35 to 115 gsm has been used depending on the printing
method.
2. The paper should be sufficiently strong to prevent the tearing in high speed
printing.

3. The paper has to be dimensionally stable during transfer process to avoid image
distortion.
4. Good release of dye vapours from the ink layer.
5. Stability to heat up to 2200C.
6. Paper should have a smooth surface.
7. Paper should be free from metal because some disperse dyes are metal
sensitive.

Inks used in transfer printing:

Inks used in transfer printing are made up of

Dyestuff + Vehicle +Thickener

 Some selected and special quality dyestuffs with required characteristics are
used as dyestuffs for making inks. The dyes should sublime at high temperature.
 Vehicle makes dyestuff dissolve e.g. sprit, glycol, tolune, ethyl methyl ketone,
iso-propanol etc.
 Thickeners act as binding agents and impart viscosity e.g. Polyvinyl acetate,
cellulose esters, acrylic resins etc.

2. Wet or migration transfer printing:

The principle behind wet transfer processes is the use of water as the medium through
which dye diffuses in passing from the paper to fabric.

 It should contain soluble ionic-dye.

 This is suitable for cellulosic fibre printing.
The technique of printing consists essentially of Three (3) simple steps-

1st Step: The pattern/design is printed on a special grade paper by paper printing or
modified textile printing machine using printing ink containing water soluble substantive
dyes (suitable dyes for suitable fibres).

2nd step: The fabric is impregnated with a mixture containing water, dye carrier, dye
fixation, catalyst etc. at the boiling temperature of the bath. In case of cotton fabric
printing the cloth is padded with alkali, salt, urea and other auxiliaries (if necessary).

3rd step: The transfer of printed design/ pattern from the paper to textile substrate is
effected by forming a sandwitch of printed paper and impregnated wet fabric followed by
application of required pressure and temperature for a fixed time of contact in a suitable
machine specially developed for this purpose.

3. Film release transfer printing: As the name implies, film release deposits the
printed image, as a virtually coherent film on the textile material.
 The paper is printed with highly flexible polymeric film containing dye and fixing
agents.
 This film is then transferred on the fabric by application of heat and pressure i.e.
The production of the transfer print may be carried out using a transfer press at
1650-1900C for 10-20 sec. During this period the film softens and is forced into
the fabric. After removal from the press the composite is allowed to cool and the
image to reset. The paper can then be removed.
In this case the transfer does not depend on any property of dye such as volatility and
solubility but depend on polymeric film which becomes tacky at transfer temperature
and provide good adhesion on fabric.

Advantages of this system over other transfer printing system:

1. Any type of dyes can be used because it does not depend on volatiles or
solubility of dye.
2. Any type of fabric can be printed by this system.
3. Less pressure required but same heat is needed as in heat/sublimation transfer
printing.
4. Contact time is very less compared to other process.
5. Even pigment, metal, powder etc can be transferred.
6. 100% transfer can be achieved.

4. Melt/Thermochrome transfer printing:

It comprises a grease proof paper printed with a design on wax based inks and transfer
is carried out above the melting point of wax using high pressure.

The transfer is on mechanical embedding of ink layer to the fabric rather than volatility
or solubility.

Advantages of Transfer printing:

 The capital cost of the equipment is low.

 Space requirement is also small.
 A skill printer is not required though careful control of temperature and pressure
is needed.
 A clear and sharp definition of all objects is possible
 The proportion of sub-standard quantity is as low as 2%.
 Since the printed fabric does not need any treatment, it does not contribute to
water pollution problem.
 It gives good prints on well prepared knitted goods.
 No adverse effect on fabric feel and luster.
 It allows excellent dye penetration into the fibre (because transfer takes place at
very high temperature.)
 Steaming, washing, drying etc are not necessary.
 Quicker reactions to changes in fashions, shorter delivery time.
Disadvantages of Transfer printing:

 There is some restriction of the production of deep shade

 Sublimation fastness is low.
 Once printed cannot be corrected
 Only limited dyestuff can be used for transfer printing.
 Storage of large quantities of paper over prolonged period of time is a risk.
 Lack of color brilliance in case of Polyacrylonitriles and blends of wool and
cellulose with synthetic fibres.