Reactive printing and its different process

Introduction

Reactive dye printing, a well-liked and inventive technique for adding color to textiles, is renowned for its vivid colors, colorfastness, and adaptability. This manual explores the history, chemistry, methods, advantages, and uses of reactive dye printing, delving into its complexities.

Reactive dye printing: What is it?

Reactive dyes are used in reactive dye printing, whereby they create a covalent link with the fabric's fibers. The dye and the fiber form a strong chemical link as a result of this reaction, which guarantees that the dye is incorporated into the fabric. As a result, the colors are bright and durable, resistant to fading and light exposure.

The History Of Early Developments of Reactive Printing 

Imperial Chemical Industries (ICI) of the United Kingdom initially introduced reactive dyes in the 1950s. Dyes that attached themselves well to natural fibers, such as cotton, were scarce prior to their development. Reactive dye technology represented a substantial advancement in textile printing and dyeing.

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Innovation and Evolution

Reactive dye chemistry and application techniques have changed throughout the years. Reactive dye printing is a popular technique used nowadays on a wide range of fabrics, including silk, cotton, wool, and even synthetic fibers. New types of reactive dyes have been developed as a result of ongoing research and innovation, providing improved performance and environmental benefits.

The Structure , Properties and Chemistry of Reactive dye

Reactive groups, which create covalent connections with fiber molecules, are the distinguishing feature of reactive dyes. Vinyl sulfone, dichlorotriazine, and monochlorotriazine are the bases of the most prevalent reactive groups. These groups interact with amino groups in protein fibers or hydroxyl groups in cellulose fibers.

Dye Mechanism

There are various steps in the reactive printing process:

• Application: 

A variety of methods, including screen printing and inkjet printing, are used to apply the dye to the fabric.

• Fixation: 

In the presence of an alkaline agent, the dye combines with the fiber at a high temperature.

• Washing: 

The fixed dye molecules remain covalently bound to the fiber after excess dye and chemicals are removed.

Benefits of Reactive Dye 

1. Reactive dyes come in a variety of vivid and bright colors.

2. The colors are resistant to rubbing, washing, and light exposure because to the covalent bond.

3. Works well with a range of natural and some synthetic fibers.

4.  A lot of today's reactive dyes are made with less energy and water in order to be more environmentally friendly.

Methods of Printing with Reactive Dye

Using a Screen

One of the most popular techniques for incorporating reactive colors into textiles is screen printing. It entails making a stencil, sometimes known as a screen, and using it to dye the fabric.

• Preparation: 

To guarantee uniform dye absorption, the fabric is cleaned and treated with a solution.

• Screen Preparation:

For every color used in the design, a screen is made. To create the design, portions of the screen have been masked out.

• Dye Application: 

After applying the dye to the screen, it is pushed onto the fabric through the open areas.

• Fixation: 

To fix the dye, heat is applied to the printed fabric.

• Cleaning: 

To get rid of any chemicals and unfixed color, the fabric is cleaned.

Printing Digitally

Reactive dye digital printing is a relatively recent technology that provides excellent flexibility and precision.

• Design: 

Digital software is used to generate the design.

• Printing: 

Reactive dye ink-equipped specialized inkjet printers print the design directly into the fabric.

• Fixation: 

To fix the dye, the fabric is steam-pressed.

• Washing: 

Extra coloring is removed by washing.

Printing using Heat Transfer

Using pressure and heat, heat transfer printing transfers dye from pre-printed paper to fabric.

• Design: 

Reactive dye inks are used to print the design onto transfer paper.

• Transfer: 

The dye is applied to the cloth by placing the transfer paper on it and applying pressure and heat.

• Fixation: 

To fix the dye, the fabric is steam-pressed.

• Washing: 

To get rid of extra dye, wash the fabric.

Alternative Techniques

Reactive dye printing can also be achieved by batik, tie-dye, and resist dyeing, each of which has a different visual impact.

Uses of Reactive Dye Printing in Clothing and Accessories

1. The fashion industry frequently uses reactive dye printing to produce vivid, long-lasting designs on clothing. Reactive dye-printed textiles are a mainstay in fashion, appearing on everything from t-shirts and gowns to scarves and shawls.

2. Reactive dye printing is frequently used to create enduring and colorful designs in home textiles like upholstery fabrics, bed linens, and curtains.

3. Reactive dye printing processes are used by artists and craftspeople for a variety of projects, such as personalized apparel, textile art, and home décor.

4. Technical fabrics, such as protective apparel and medical textiles, where colorfastness and durability are crucial, also use reactive dye printing.

Problems and Solutions

Fixation on Dye

Making sure the dye is completely fixed is one of the difficulties in reactive dye printing. Poor fastness qualities and color fading might result from incomplete fixing. This problem can be lessened with careful fabric pretreatment, ideal dyeing conditions, and appropriate washing.

Impact on the Environment

Reactive dyes demand a lot of water and energy to dye, even though they are often more environmentally friendly than other dye kinds. These issues are being addressed by innovations like biodegradable dyes and low-water dyeing methods.

Price

Because reactive dye printing requires precise processing conditions and expensive dyes, it may be more expensive than other processes. Nonetheless, colorfastness and vibrancy frequently outweigh the price.

Prospects for Sustainable Practices in Reactive Dye Printing in the Future

Sustainability is becoming a bigger priority for the textile sector. The creation of environmentally friendly dyes, waterless dyeing techniques, and energy-efficient procedures are some of the upcoming trends in reactive dye printing.

Technological Progress

As digital printing technologies advance, they provide increased accuracy, adaptability, and productivity. New creative possibilities and wider acceptance are expected to result from advancements in digital reactive dye printing.

Smart Textiles: 

Reactive dye integration with smart textile technology is a promising field of research and development. Innovative applications involving reactive dyes that react to environmental cues like UV light or temperature changes are being investigated.

In summary

With great color fastness and a plethora of uses, reactive dye printing is a flexible and colorful way to color textiles. Reactive dyes produce stunning, long-lasting effects on a variety of textiles, from smart and technological textiles to fashion and home textiles. Reactive dye printing will continue to be a cutting-edge and essential component of the textile industry as sustainability and technology progress.