How digital Textile printing amplifies the Rotary printing Business?

Digital Textile Printing and Conventional Rotary Screen Printing have their own benefits providing unique & versatile opportunities for printing houses. The smarter choice would be to combine both of them to extract the most advantages from these individual technologies.

A garment supplier has to prepare a number of samples in their product development process before receiving the final approval for production from the buyer. One of the main issues faced by a garment supplier or a production house is the cost of sampling. Sometimes, it is higher than production prices. To reduce the sampling cost, It’s a smart choice to combine both digital & rotary printing machines.

Existing conventional rotary printers face below problems associated with rotary sampling:

Loss of shift - Sampling in production rotary machine would generally take a complete shift which otherwise could have been used for printing at least 8000 meters of fabric & this results in a higher sampling cost.

Screen cost - Screen printing needs individual screens for every color and large yardage. The same needs to be created for sampling which might need changes post sample approval or rejection, which increases the sampling cost.

Fast fashion supply chain time - Screen printing needs individual screens for every color and large yardage. The same needs to be created for sampling which might need changes post sample approval or rejection, which increases the sampling cost.

Limited Color patterns and gamut will not be a solution as they need to replicate or reproduce the design on their existing 4/6/8/12 color rotaries.

Worried about the difference between Digital Sampling with Production run?

At ColorJet, our Rip software is specially developed to help our customers to come out with the best possible match in terms of the print quality of digital & rotary samples. The software maps the raster over the digital printed sample and helps to replicate the exact image. However, there may be minor differences between the final results of the two print samples but it’s overshadowed as compared to big issues like loss of shift & high sampling cost.

Print Cost Calculation

Below is a comparative case study of print cost for Rotary & Digital Textile Printing, for Reactive printing. The cost advantages of Digital Textile Printing are limited to the fact that screen cost becomes higher with the number of colors included in the design.

The above graph shows that the turning point for 5 color design (reactive printing) is about 500 kg (approx). This is the point above which the production cost increases for digital printing in comparison to rotary printing.

Apart from sampling, Digital Textile Printers will help in changing the business model of the already existing Rotary customers.

Change in apparel supply chain

Digitalization has changed the whole concept of the apparel industry. Consumers now are more comfortable in online apparel shopping as it has the advantage of a lot more options in their hands from the latest trend collections. Fashion brands are coping up with the trend, providing their customers large variety of design keeping in mind the rapidly changing fashion trends. The garment suppliers should be ready to provide the buyers with any new order irrespective of MOQ in a short time frame. A digital printer will help the processing houses in this scenario.

More freedom to textile designers

Imagination should be the only limit. All the leading apparel brands in order to top the list in the competitive fashion industry would like to give their designers the liberty to make any design without worrying about limited color options or complicated design patterns. This can only be achieved with the help of Digital Textile Printer.

More sustainable production

Sustainability is now the demand of the consumers and this has pushed all the manufacturers to opt for sustainable printing. At the first glance, it may seem that digital textile ink price is much higher than the conventional dyes used in rotary but it's much less as compared to the water & energy savings. ColorJet’s cutting-edge technology helps to reduce ink consumption significantly (approx. 20%) for the same design in comparison to other digital printers in the market. It also helps to minimize chemical waste offering a healthy working environment for the workers as well.

So what are you waiting for?

Connect with us for a profitable and sustainable print business.
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