Burnout Wash a Secret process used washingplant done by textile chemicals ( special auxiliary) . World wide many textile used A Full Package Screen Printing ,
Burnout wash uses a chemical process where the cotton fibers are removed from the garment . BURN OUT PRINT
DETAILS OF BURNOUT PRINT
Nowadays Print is a very very important thing for this textile sector. Print makes a clothes attractive. We can’t imagine a dress or clothes without print. Printing sector is also expanding and changing every day with the fashion trend. We are discovering new technic and qualities of print day by day. Print technology is growing up with the Clothes industry. 99% fashion clothes are now must have any print on it.
There are many kinds of print we can doonthe clothes or fabric. Some print very basic and normal, these prints are very cheap also. But some print is very critical and rare. These kinds of print are more costly than basic normal print. But print makes a dress or clothes attractive and saleable.
Today I will introduce you with a rare, critical and costly print. The name of this print is Burnout print. This is a rare quality print. Burnout printisalso very expensive too. It's a very nice quality print.
In the image of the print you will clearly see the Polyester and cottonpart. I'm uploading several pictures of burn out print.
The printing factory makes this print with the flat bed printing machine. The printing way of this print is same as a normal flat bed print, just printers use acid type chemical instead of color.
We can do this print only some selected fabric. This print is not possible on 100% cotton fabric. The best composition for this burn out print is 60% polyester and 40% cotton fabric. This print is also possible on 60% cotton and 40% polyester.
The main technique of burnout printis destroysthe cotton portion of the fabric with Acid / Chemical. When the chemical flow over the fabric and contact with cotton portion, then itburnout the cotton by chemical reaction. Actually cotton is the victim here.
TheBurn outchemical (Acid) and working details as mentioned below
1. PC or CVC fabric.
2. Paste Any acidliveratingsalt (like Nacl, Na2 so4)
3. Steaming
4. Washing (Roubasting wash)
5. Burnout print complete
Only print technicianswill understand the above 5 points.
Please find below the step by step printing processofburn out print.
1st Step: Develop the print design and screen with the buyer provided artwork.
2nd Step: Knit the fabric with the yarn offollowingcomposition a) 60% polyester 40% cotton OR b) 40% polyester 60% cotton Or similar like that.
3rd Step:After complete the kitting of fabric send the gray or scouring fabric to printing factory.
4th Step: Perform the print on this fabric. Here, the cotton part will be destroyed by the acid but polyester portion will be remain same.
5th Step: Then we will dye and finished the fabric as per our require color.
Hope, above description of burn out print is clear to all.
Now please find below some important points regarding the Burnout print-
1. Burnout print is not possible on 100% cotton fabric. Clothes should be PC or CVC
2. 60% polyester 40% cotton is the best compositionforBurnout print.
3. Process loss is very high. More than 35%
4. Single jersey construction is the best construction for Burnout print.
5. If you need the finished fabric with 120 to 130 GSM then you should knit the fabric with 160 to 170 GSM.
6. Burnout print is not only expensive but also lucrative with nice feelings.
When you will calculate the cost of a burnout printed dress or clothes, please follow the below details-
1. Please add the burnout print price with fabric price.
2. As the sampling cost is very high so also consider it during the pricing.
3. Add process loss 35%
4. Normally the cost of burnout print is $4.5 to $5.0/kg
Please find below the costing details of single jersey Burnout fabric.
( Thisis an example only, pricemay changedany time)
1. Yarn per Kg = $ 3.60
2. Fabric Knitting = $ 0.15
3. Scouring = $ 0.80
4. Burn Print = $ 5.00
5. Wash = $ 0.80
6. Dyeing = $ 1.50
---------------------------------
Total = $ 11.85/Kg
Add process loss = 35%
The finish Burn out Fabric cost will be = $ 16.00/Kg Post By Enamul Haque Bipul Chemicals:
Synthetic Thickener, Sodium Bisulfate, Penetrating Agent, Glycerin and Water.
Purpose:
Burnout is a beautiful effect, Which is carried out on blend fabric and specially for those blends which have high percentage of cotton and are reserved dyed (mean polyester portion is either dyed or printed), when cotton burns down dyed polyester gives full shade and vacant spaces. One can literally see across this type of effect.
One can take simple white fabric, blend of course. Dye or print it with disperse dye in acidic medium than apply burn out recipe afterwards go for reduction cleaning which is required for polyester. This cleaning will also wash down burned cotton.
Cotton can be chemically burn out at 200C in presence of Sodium bisulfate (other chemicals were also tested in order to substitute sodium bi sulfate , which is discussed in later portion)
As a big house Masood textile on its website expresses.
Preview this picture on large scale
Defining Burnout according to www.answer.com
Burn-out textiles is a technique used to develop raised designs on fabric surface.This is primarirly being done in fabrics with atleast 2 different fibre content i.e Cotton-Polyester , Silk-Rayon etc.Here one fibre component is being dissolved thru chemical reactions while the other content remains intact giving away raised illusion designs
Cotton Portion had blue where as polyester is having no color. So, during burn out cotton burns down leaving only polyester portion resultantly only white shade on burnt region and a wonderful pattern appears. Isnt it?
Recipe:
Stock paste:
Synthetic Thickener 8% Balance
Sodium bisulfate(1:2) 300g/Kg
Glycerin 50g/Kg
Penetrating agent 20g/Kg
Total1 Kg
Note:
* (1:2) mean dissolve 150g of Sodium bisulfate into 150g of water and than added to remaining recipe. This is to have 100% soluble bisulfate.
* Thickener is never added instantly, Rather it is added into recipe at high stirring with slow sprinkle. It will form agglomerates if added in once. So never add at once rather sprinkle it into glass at high speed stirring.
* Synthetic thickener here can be of poly saccharides based chemistry.
Process:
Print and dry at 110-120°C for 1Min.
Cure at 200C for 1 Min
Note:
*Curing time and temperature are needed to be pre tested (Lab Trial), Some time while using light blends, Polyester portion also get damaged. So, Consequently no good. One can choose one of these temperatures and times
1.160C @ 5Min
2.180C @ 2Min
3.200C @ 1Min
Options:
Chemicals other than Sodium Bisulfate were also tested for this experiment. e.g.
1.Sulfuric acid Full Black Effect (No Burning)
2.Sodium Hydosulfite (No Burning)
3.Sodium Bisulfite (No Burning)
Burnout On Garment
Remarks:
Burnout is a great effect. It is adorable and seems pretty. Synthetic thickeners are usually polysaccharide based and normally used in disperse printing of Polyester Fabrics. This thickener is readily available in market. It is not something like special thickener which we used in our washingplant
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