Kornit Apollo: Garment Production Goes Automatic

Every once in a while a machine hits the market that makes you take a step backwards as it redraws a number of lines you thought were there forever. Not only do you need to take a metaphorical step backwards when considering the new Kornit Apollo direct-to-garment (DTG) printer, you actually need to take a physical step backwards too due to its physical size.

Looking at the machine, it is configured into two specifically different sections, one for the printing of the garment, the other for the drying of the printed product. Connecting the two is the loading section and next to it is the user interface; meaning the operator needs to be front and centre of the machine in order to operate it.

In a very basic description, the garment travels to the right of the operator once it is loaded. Once printed, the garment drops below the printing line and reverses direction and travels to the left, along the length of the printing section and under the loading area. A 90-degree change in direction removes the garment from the cassette on which it was printed, prior to taking a second right turn as it passes through the drying section.

This clever, ingeniously designed machine means a single operator is required to load, prepare, and remove the garments at the listed speed. This means production levels are set to soar whilst the manning level drops in the opposite direction.

The Devil is in the Detail

The layout description of the Kornit Apollo was deliberately simplistic to set the background for just how you get those 400 garments fully printed and dried without anyone touching them, but now for the detail as to how.

Breaking down the process, the garment firstly is scanned with a hands-free device; this will now dedicate the machine to printing this one garment. The details for the finished product are stored on the machine and it then adjusts the size of the pallet dedicated to the garment. This is done via a robot system which adds or exchanges the required number of pallet sections depending on the garment size.

The only operator interaction takes place next whilst the operator loads the virgin garment to the pallet dedicated to it. The loading is semi-automatic as the Kornit Apollo ensures the product is accurately positioned and evenly stretched to remove any slack or overtightening. This is only one of a number of elements of the design which ensure consistent product quality.

The pallet now starts its unique journey through the machine, the first stop being the pre-treatment where a customised amount of fixation fluid is applied to the garment from the details scanned and stored by the earlier stage.

As with most quality garment printing, a white base layer is needed and on the next station this is the same with the Kornit Apollo. Again, as each garment has a unique barcode, the specific amount and spread of white ink is applied, demonstrating yet another element of the quality circle.

Next up is the feature item, the application of colour. The Kornit Apollo Dimatrix Starfire 1024 Twinflex head applies the standard CMYK ink set but with additional channels for red and green. Added to the range of colours that can be applied, the printheads can apply the ink at 1200dpi meaning the colour quality available for a garment is as high as that for general printing.

The inks themselves are the NeoPigment Eco-Rapid from Kornit and as you would fully expect, they are fully compliant with the highest eco-standards and hold the OEKO passport certification. The machine takes a far wider view of sustainability as it also holds the Global Organic Textile Standard (GOTS) and is a Bluesign System partner.

Each garment is prepared, precoated, and printed automatically meaning quality is totally consistent

As described above, the pallet now drops and starts its journey onto the drying system in the other section of the machine. Each of the loaded pallets move quickly and seamlessly under the printing section which then rise to the other side so the top of the garments are ready for unloading.

No operator intervention is needed to unload the garment as the pallet releases the product with the four corners delicately held as the machine moves the printed, but uncured garment, onto the drying conveyor.

The large drying tunnel features Tesoma drying technology meaning the energy dependent element of the machine is running to optimum levels to ensure the products are dried ready for dispatch post-production.

All in One Solution

What needs to be considered with the detailed process above is each of the steps is being taken concurrently with each pallet being loaded. The machine is garment hungry as this is a continuous process with the operator needing to have the unprinted sheet piled ready to scan and load.

Previously if you were seeking to print high volumes of garments the logistics would have been quite demanding having to print, stack, and dry them individually. Added to that, maintaining quality across the batch with a manual set of processes would be equally as problematic.

Whilst the actual production is all contained within the machine, ensuring maximum efficiency levels, the Apollo DTG printer comes with Kornit’s exclusive RIP solution. Clearly there are a number of different software platforms available but K-RIP is designed to enhance production on garments meaning customisation is easy, and that colour accuracy for brand spot colours can be guaranteed.

The Kornit Apollo DTG machine takes production to a whole new level of quantity and quality whilst maintaining excellent levels of sustainability and user safety. Whether your production is 1,000 T-shirts for a large publicity event or kit for the local football team across a range of sizes, the Kornit Apollo can deliver for any occasion.

Statistics

Colour CMYKRG + W + Q.fix + Intensifier
Inks NeoPigment Eco-Rapid
Maximum print area 508 x 508mm
Resolution 1200dpi

Brian Sims Principal Consultant, Metis Print Consultancy, www.metis-uk.eu