Disperse printing application and problem solving

Disperse printing is an efficient dyeing process for synthetic fibers such as polyester, especially suitable for textiles with bright colors and complex patterns. The process is based on disperse dyes and combines heat transfer, high-temperature fixation and other technologies. It is widely used in the fields of clothing, home textiles and industrial textiles.

I. Typical problems and solutions

1. Color migration (Flocking)

Cause: The dye is not completely crystallized and re-sublimates during storage.

Countermeasures: Add anti-migration agents (such as polyethylene wax emulsion) and increase the baking temperature by 5-10℃.

2. White ground contamination

Prevention: Use a refining agent (non-ionic surfactant) in pretreatment to completely remove fiber oligomers.

3. Decreased pattern clarity

Improvement: Use high-precision nozzles (such as Ricoh GEN6 nozzles, with a minimum ink drop of 3 pL) to improve edge sharpness.

II. Industrial application cases

1. Sportswear field

Demand: Long-lasting printing of highly elastic fabrics (polyester-ammonia blends).

Solution: Direct printing + elastic fixing agent (polyurethane modified resin), stretch recovery rate > 85%.

2. Automotive interior textiles

Challenge: Light fastness > 7 (ISO 105-B02).

Technology: Anthraquinone disperse dyes (such as C.I. Disperse Blue 56) and UV absorber coating treatment.

3. Fast fashion digital printing

Business model: ZARA uses disperse dye direct printing system to achieve a 72-hour "design → shelf" cycle.