Detailed Project Report on pigment print binder

PIGMENT PRINT BINDER
[CODE NO.3714]  

    
Of the print systems used on cotton in the textile industry, pigment printing accounts for as much as seventy percent of the total. This system requires no pre or post treatment other than drying the fabric. The color gamut is wide, and the sharpness of prints is excellent. Pigments do not react with the cotton fiber and must be adhered to the fabric with a film forming binder, which may detract from the hand of the fabric. However, advances in binder systems have made positive contributions to print performance.

Special effects are used in addition to or in combination with pigments to impart a unique look to fabrics. Some of the special effects examined in this bulletin include resist, discharge, and burnout techniques. Alternative pigment types such as thermotropic, phototropic, puff, and plastisol technologies will also be described.

A textile pigment print system includes the following parameters:

•    Pigment: A pigment colorant is a colored organic substance that is not readily soluble in most common solvents and imparts coloration to textile substrates only when incorporated with an adequate binder system.

•    Binder: A pigment binder is the latex polymer resin that forms a three-dimensional film on the surface of the fiber. This film contains the dispersion of textile pigment and will act to adhere the pigment to the surface of the substrate. The permanence of this film is dependent on the polymer type and the application conditions. Binder chemistry, performance, and application is covered in Technical Bulletin ISP 1008.

•    Thickener: The pigment system is composed of the textile pigment dispersed in the polymerizable resin binder, which is further mixed into a synthetic thickener system, comprised of a long chain acrylic acid. The thickener enables the pigmented print paste to stay in place once it is deposited onto the fabric prior to drying. This system is applied to the textile substrate by the following means: rotary screen printing, flatbed screen printing, engraved roller printing, coating, padding, spraying, or immersion.

Coloured pigments (as well as titanium dioxide) can be fixed onto the fibre surface though they are not bound to the fibre substance either by covalent bonds or by any other bonds normally presents between dyes and fibre substance like ionic bond, hydrogen bond, Vander waals forces etc. This is achieved in pigment printing by using suitable binders, which form transparent, soft, pliable films, which trap the pigment particles between the film and the fabric surface and react with the fibre surface.


COST ESTIMATION


Plant Capacity            2 Ton/Day       
Land & Building (600 sq.mt.)      Rs. 90 Lac         
Plant & Machinery                      Rs. 40 Lac     
Working Capital for 2 Months     Rs. 54 Lac
Total Capital Investment              Rs. 1.93 Cr
Rate of Return            24%                   
Break Even Point             66%                



INTRODUCTION    
A TEXTILE PIGMENT PRINT SYSTEM INCLUDES THE FOLLOWING PARAMETERS    
PROPERTIES    
PIGMENT PRINTING    
APPLICATION OF PIGMENT PRINTING    
B.I.S. SPECIFICATION    
BASICS OF PIGMENT PRINT PASTE FORMULATION    
FIGURE. VISCOSITY AND FLOW    
THICKENER OR CLEAR-EXTENDER PREPARATION    
AUXILIARIES USED IN PIGMENT PRINTING    
ADVANTAGE OF PIGMENT PRINTING    
PRINTING PRINT BINDER AND ITS APPLICATION    
PASTE PREPARATION PROCEDURE    
TYPICALLY PIGMENT TO BINDER RATIO SHOULD BE MAINTAINED 12.5 TO
GET GOOD FASTNESS.    
TO OPTIMIZE BINDER CONSUMPTION FOLLOWING METHODOLOGY IS FOLLOWED    
IMPORTANT NOTE    
BINDER ECONOMICS    
STORAGE & SHELF LIFE    
GLOBAL OVERVIEW OF TEXTILE AUXILIARY    
OVERVIEW OF TEXTILE PRINTING IN BANGLADESH    
PROJECTED DIGITAL AOP CLOTHING MARKET SIZE IN VALUE (USD IN BILLION)    
MARKET POSITION OF APPAREL AND READYMADE GARMENTS    
APPAREL EXPORT IN TWO SEGMENTS (WOVEN AND KNIT) FROM 2014 TO 2018.    
EVALUATION OF APPAREL EXPORT VALUE FROM 2014 TO 2018 CALENDAR YEAR.    
2018’S APPAREL EXPORT FACTS.    
BANGLADESH’S APPAREL EXPORTS EARNINGS TO NON-TRADITIONAL MARKETS.    
FORMULATION AND PROCESS OF PIGMENT PRINTING BINDER    
FORMULATION - 1    
PART A EMULSION COPOLYMER PREPARATION (50 % SOLID)    
PART (B) MODIFIED UREA FORMALDEHYDE PRE-CONDENSATE PREPARATION    
FINISHED BINDER (C)    
PROCESS FLOWSHEET UREA-FORMALDEHYDE PRECONDENSATE    
PIGMENT PRINTING BINDER    
FORMULATION - 2    
PROCESS FLOW DIAGRAM    
COMPONENTS OF PRINTING PASTES    
PIGMENT PRINTING RECIPE AND PROCESS    
PIGMENT PRINTING RECIPE    
PIGMENT PRINTING PROCESS    
FORMULATION AND PROCESS OIL IN WATER EMULSION FOR PIGMENT PRINTING    
PROCEDURE OF PREPARATION OF OIL IN WATER EMULSION THICKENER    
PREPARATION OF THICKENER PASTE    
1. THICKENER WITH WATER    
PREPARATION OF PRINTING PASTE    
PRINCIPLES OF PLANT LAYOUT    
PLANT LOCATION FACTORS    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
PROJECT IMPLEMENTATION SCHEDULES    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY


APPENDIX – A:

01.    PLANT ECONOMICS    
02.    LAND & BUILDING     
03.    PLANT AND MACHINERY    
04.    OTHER FIXED ASSESTS    
05.    FIXED CAPITAL    
06.    RAW MATERIAL    
07.    SALARY AND WAGES    
08.    UTILITIES AND OVERHEADS    
09.    TOTAL WORKING CAPITAL    
10.    TOTAL CAPITAL INVESTMENT    
11.    COST OF PRODUCTION    
12.    TURN OVER/ANNUM    
13.    BREAK EVEN POINT     
14.    RESOURCES FOR FINANCE    
15.    INSTALMENT PAYABLE IN 5 YEARS    
16.    DEPRECIATION CHART FOR 5 YEARS    
17.    PROFIT ANALYSIS FOR 5 YEARS    
18.    PROJECTED BALANCE SHEET FOR (5 YEARS)