The following is an exceprt from a presentation by Andy Graven of Zenith Engraving outlining the benefits of digital printing use. Included in this summary is a cost comparison between traditional rotary screen printing and digital printing for sampling. For additional information, please contact Andy at agraven@zenithengraving.com.

Digital Textile Printing

A Great Way to Save Printing

Andy Graven

Zenith Engraving Company, Inc.

November, 2002

Digital Printing Objective

nProvide large cost reduction for converters and printers.

nSignificantly increase new product choices.

nShorten time to develop new products.

nLeverage expertise in color separation.

nProvide opportunity for printing to remain in the USA.

Current View of Digital Technology

nMeans to sample design within studios

nEnables sampling of designs at customers

nVariable color matching ability

nLimited ink types available for prototyping

nSlow speeds inhibit production capability

nMost printers produce “photographic” quality, not predictive of rotary printed goods.

Current Printer Equipment

nIchinose ImageProofer

nStork Amethyst

nDupont Artistri

nMimaki TX2-1600

nEncad NovaJet 880

nZimmer Chromotex

nColorSpan FabriJet

nAprion Magic

nLeggett & Platt Virtu

nMost producers have reactives & acids in various colors.

nFew producers have disperse inks.

nFinishing inks for light, color, & wash fastness possible.

nMany producers developing pigments; color depth & range vary.

nOffers biggest challenge & opportunity.

Mid-Term View of Digital Technology

nMost designs are previewed digitally

nColor matching not an issue

nMore ink types available and easier post treatments - enabling finished goods

nFaster printing speed

nLimited production more routine

nCustomers’ general acceptance of the digital process.

Long-Term View of Digital Technology

nDifferent digital printers available for sampling, prototyping and production

nColor and mark commercially acceptable by designers & consumers

nOne-step pigment inks

nPrinting speeds at 150 -300 meters/hour

nMore custom printing than ever before

nLess printing off-shore.

This is Zenith’s experience thus far…

nProvides low cost, fast service to customers

§Samples of patterns

§Various color combinations

§Limited yardage

nPrints on any fabric: sheeting, jacquard, knits, towel

nPrecise color matching and repeatability

nExact “mark” of rotary or flat screen printing

nReactive inks provide excellent color range

nSpeed: 10 sq m/hr.

Zenith’s Choice of Technology

Ichinose ImageProofer with Tschudi software

n12 colors allows excellent color range

nThermal inkjets provide better than average coverage & penetration

nCustom software enables digital print to match mark of commercial printer

nExisting color separation skills used extensively

nUsed to pre-sell designs that simulate rotary screen-produced yardage.

Approach for Using Digital Printing

There are two methods for introducing new patterns:

n(1) Conventional, most common & current method

n(2) Using digital technology for printing fabric colorways and sample yardage

nBoth have their merits; the bottom line is cost, speed and commercial success

nZenith believes the digital process will save significant cost & time for printers and converters.

Assumptions for this Analysis

This analysis will be used to compare the methods:

nAverage 10 patterns/line & 10 colors/pattern

n Patterns are all 27” repeat size; 77” length

nAll flat colors

n10 colorways /pattern for TSO cost analysis

n4 colorways/pattern for sample yardage - 2000 yards each.

Cost for Conventional Method

Converters cost for conventional method of introducing a pattern:

Elements                                                       Cost Est.

npattern(design internally or purchase)     $1-3,500

nengrave screens                                        $5,000

nblotter to confirm engraving quality          $60

nTSO’s for colorways (10@$60)               $600

nsample yardage (4 colorways)                 $20-30,000

nproduction on selected colorways           unknown

                          TOTAL                               $25,000+

Printers cost for conventional method of introducing a pattern:

Elements                                                     Cost Est.

norder, then inventory screens                  $500

nblotter to confirm engraving quality         $400+

nTSO’s for colorways (10@$150)            $1500

nsample yardage (4 colorways)                $10-13,000

nproduction on selected colorways           unknown

                     TOTAL                                   $12,000+

Cost for Digital Fabric Prints

nThe digital fabric approach includes color separation for 10 colors and 2 yard samples of 10 colorways priced at:

nModerate (this example)         $3500/ pattern

nIf screens are engraved from the above, the price will be:

nModerate (this example)         $3100/ pattern

Cost Comparison

For a 10 pattern line…

nConventional method would cost converter at least $250,000

nConventional line would cost printer at least $120,000

nDigital fabric printing cost would vary with the success rate of the line; for moderate patterns:

nDigital fabric prints of 10 colorways would cost $35,000.

nSample yardage of 4 colorways would cost about $36,000.

nScreens would cost $24,800 at 80% success rate; $18,600 @ 60%; and $12,400 @ 40%.

Example of Savings

Assuming 60% of the patterns are commercially successful, the cost for a converter to evaluate the entire line using digital fabric prints would be:         

Elements                                                  Costs

nDigital fabric colorways-10 patterns     $35K

nSample yardage-10 patterns                $36K

nScreens for 6 patterns                           $19K

                                                TOTAL        $90K

SAVINGS = $250K-$90K = $160K (64%)

nNo costs until print order received

nAvoid $12,000+ for pattern development

nNo wasted dye, labor or lost fabric at strike-off

nColor match would be completed at beginning of production, same as now - some extra costs, but offset by production of pre-sold yardage.

nCould change use of strike-off table: as aid to printer for color management on machine.

nShould result in more efficient operation - lower costs, higher productivity.

Time to Introduce A New Product

Future Needs & Impact

•Significantly faster printer speeds = Increased production of digital fabric

•Pigment inks with good color depth & range = Prototyping with finished fabric

•Finishing capability for small scale samples = Prototyping with finished fabric

•Savings shared throughout the chain = Lower cost USA
made goods

Summary

Digital textile printing …

nProvides opportunity for significant savings.

nProvides faster product to market.

nNeeds to be fully utilized.

For more company information, visit www.zenithengraving.com.

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