How to Achieve Zero Wastewater in High-Energy Disperse Digital Printing? - HONGSAM Washing-Free High-Energy Disperse Ink Has Been Launched

Abstract:

In response to the high-water consumption challenge in the textile printing and dyeing industry, HONGSAM has introduced its Washing-free High Energy Disperse Ink. This innovative product completely eliminates the traditional “reduction clearing” step in high-energy disperse printing, solving long-standing issues of heavy water usage, massive wastewater discharge, and high treatment costs. It ushers the textile printing sector into a new era of zero wastewater discharge, high efficiency, and lower costs.

As a high-tech enterprise with over 20 years of deep expertise in digital inkjet printing, HONGSAM has consistently led the way in green printing and dyeing technology. In the field of disperse inks, the company is not only a technology innovator but also a setter of industry standards. The launch of this Washing-free High Energy Disperse Ink marks HONGSAM’s successful breakthrough in solving the decades-old “wastewater discharge” problem and fills a critical gap in domestic processing technology.

I. Industry Background: The Washing Dilemma in Traditional Printing and Dyeing

In the textile printing and dyeing industry, the traditional high-energy disperse printing process has always required one unavoidable step: reduction clearing. While this step improves fabric quality, it also causes excessive water consumption, high wastewater treatment costs, and extended production cycles.

According to the Printing and Dyeing Industry Specification Conditions (2023 Edition) issued by the Ministry of Industry and Information Technology, the fresh water intake for cotton, linen, chemical fiber, and blended woven fabrics must not exceed 1.4 tons per 100 meters. With increasingly strict water resource regulations, the highly water-intensive reduction clearing process has become a major “liability” restricting enterprise capacity and compliance. In addition to generating large volumes of wastewater and raising treatment costs, it prolongs production time. The use of sodium hydrosulfite and caustic soda—both hazardous chemicals—also poses safety risks.

Faced with tightening environmental policies and strong market demand for cost reduction and efficiency improvement, the industry urgently needs a real process revolution.

To meet this demand, we have developed an innovative technology — the washing-free high-energy disperse process. Through breakthrough formulations and process optimization, it completely eliminates the water-washing step, delivering a dual transformation in efficiency and environmental protection.

II. Core Technical Solution: High-Energy Disperse “Washing-Free” Technology

To address these pain points, HONGSAM has officially launched its Washing-free High Energy Disperse Ink. This solution uses groundbreaking formulation and process improvements to remove the washing step entirely, achieving both high efficiency and true environmental compliance.

The solution has already been validated through extended real-world application by customers and has received strong recognition.

The success of this solution stems from the deep integration of three core technologies:

* Nano-level Color Paste Precision Control: The use of nano-scale disperse dye pastes significantly enhances dye penetration and fixation rates, greatly reducing unfixed dye (floating color) at the source.

* Specialized Ink Development: The high-energy disperse ink was specifically developed for the washing-free process. It delivers vibrant colors while substantially reducing floating color and improving color fastness.

* Dedicated Process Development: A tailored process overcomes the common problems of dull colors and poor fastness that typically occur without washing, fully meeting market order requirements.

HONGSAM began R&D on high-energy disperse inks more than a decade ago, overcoming numerous technical challenges to become one of the first in China to launch and successfully apply them. In 2013, its disperse direct-print dye ink was included in the seventh batch of the China Printing and Dyeing Industry Energy-Saving and Emission-Reduction Advanced Technology Recommendation Catalog, earning wide market acceptance.

HONGSAM high-energy disperse inks passed rigorous testing by Ricoh printheads years ago and remain the only Chinese brand officially recommended by Ricoh. The inks are now successfully used with Ricoh, Kyocera, StarFire, Epson, Konica Minolta, and other industrial printheads. With the new washing-free version, HONGSAM has once again broken through the long-standing technical barrier between environmental performance and printing quality, delivering a true green revolution in the disperse printing process.

III. Product Advantages: Outstanding Performance Leading the Industry

The Kyocera Washing-free High Energy Disperse Ink is not only an environmental pioneer — it also delivers exceptional performance:

* Vivid Colors: Color brightness is very close to fabrics processed with traditional reduction clearing. Large solid areas appear rich and vibrant, while gradients and fine patterns remain sharp and detailed.

* Excellent Color Fastness: Even without washing, the ink achieves outstanding dry and wet rubbing fastness, washing fastness, and light fastness.

* Superior Penetration: Compared with heat transfer printing, the printed fabric offers better penetration, with no white yarn exposure or “grin-through” effect.

* Soft Hand Feel: The washing-free process does not stiffen the fabric. The material retains its original soft hand feel and natural style.

* Effective Solution for Staining Issues: It provides a reliable solution to the industry-wide challenge of color staining on difficult substrates such as polyester suede fabrics and milk silk.

IV. Product Specifications and Process

Production Process

Pre-treatment → Printing → Drying → Steaming → Stentering & Heat Setting → Finished Product

Application Range

Suitable for all types of polyester fiber fabrics.

Conclusion: Lead the Industry with Simplicity

The birth of the Washing-free High Energy Disperse process is a milestone in the textile printing and dyeing industry’s transition toward green and intelligent manufacturing. It simplifies the production workflow, significantly reduces wastewater discharge, lowers costs, and redefines high-energy disperse printing with superior color and fastness performance.

By reducing production costs, minimizing sewage discharge, and eliminating the use of hazardous chemicals, this process gives enterprises a clear competitive edge in the market.

HONGSAM warmly invites printing and dyeing companies to discuss and explore this new technology together. Let us open the “washing-free” era in the printing and dyeing industry. With less resources and smarter technology, we can create greater value and build a more sustainable future for textiles.

References

[1] Henan Ecological Environment Service Center. Printing and Dyeing Industry Specification Conditions (2023 Edition) [EB/OL]. 2023.

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