In the textile export business, where is the highest risk? Many people think of weaving or knitting. However, the real "danger zone" is the dyeing and printing process. Weaving and knitting are physical and mechanical processes. But dyeing and printing are chemical and extremely sensitive.
Currently, the textile printing is divided into two main methods: Screen Printing and Digital Textile Printing (DTP). Both have different strengths and risks.
1. Screen Printing is the traditional leader. It is excellent for mass production because the cost per yard is low. It pushes ink deep into the fabric, providing excellent color fastness. However, it has a big financial risk. That is the cost of making engraving cylinders. If a design does not sell, the cost of the cylinders becomes a total loss. As the number of colors in a design increases, these setup costs rise significantly, and there is a physical limit to how many colors can be used. Also, the harsh work environment makes it very difficult to find skilled workers today. Processes like steaming create high temperature and humidity.
2. Digital Textile Printing (DTP) is the modern alternative. It uses digital data, so there is no need for engraving cylinders. This reduces financial risk and allows for small, fast orders. But DTP has its own technical limits. Since ink is sprayed only on the surface, Penetration is weak on thick fabrics like fleece. If you open the long pile fibers, the white base underneath may become visible. Therefore, digital printing is generally not recommended for thick fabrics like long pile fleece. Also, DTP can be more expensive for large orders. The digital printing process is much slower than screen printing.
No matter which method is used, the most critical concern for suppliers is quality claims. Specifically, color fastness (how well the color stays on the fabric) and color migration (the bleeding of colors onto other parts) are the most critical issues. Export fabrics spend weeks in hot and humid shipping containers on the ocean. During this time, if the dyeing quality is not perfect, color migration can occur, ruining the entire shipment. Furthermore, quality issues can also arise during the consumer stage. If the fabric has poor color fastness, the consumer will face bleeding and fading issues after the first wash.