Calenders for sublimation printing and sublimation printing — complete production process
Sublimation calenders are one of the most important elements of professional sublimation printing production. However, in order to properly understand their role, it is necessary to look at sublimation as a complete technological process, and not a single device. The sublimation calender does not work on its own. It is part of an integrated production line including sublimation printer, transfer paper, sublimation ink and corresponding materials, most often polyester textiles.
In this article, we explain how the sublimation printing calender works, where and how the print is made, and what to look for when choosing sublimation equipment.
Sublimation printing process and role of sublimation printer
The sublimation process always starts at the printing stage. Graphics prepared in graphic software or RIP are printed using a sublimation printer on special transfer paper. Sublimation printing is never done directly on the fabric.
The sublimation printer uses sublimation ink, which remains stable on the paper until activated by high temperature. It is at this stage that the correct image is formed, which will then be transferred to the material.
Without a sublimation printer, the sublimation calender does not have the ability to work. The calender is solely responsible for the transfer, not for printing.
What are sublimation calenders
Calenders for sublimation are thermal devices equipped with a heated shaft and a material transport system. Their job is to transfer the printed graphics from the transfer paper to the target material through controlled temperature, speed and pressure.
In the process of passing through the heating zone, the sublimation ink passes into a gaseous state and permanently binds to the polyester fibers. Thanks to this, the print becomes an integral part of the material, and not a surface layer.
Sublimation calenders are mainly used in the production of textiles, sportswear, flags, advertising and decorative materials.
How does a sublimation calender work in textile production
Transfer paper with printed graphics is precisely combined with the material, most often polyester fabric. Then both media are fed into the calender, where the roller system provides uniform guidance and tension.
The central element of the device is the heating shaft, the temperature of which is usually in the range from 170 to 210 degrees Celsius. The contact time and the sliding speed are adjusted depending on the type of material and the expected effect.
After leaving the calender, the material is ready for further tailoring without the need for additional fixation.
Calender for sublimation printing and flatbed press
In industrial production, sublimation calenders offer a significant advantage over flatbed presses. Presses work well in low volumes and unit production, while calenders are designed for continuous operation.
The sublimation calender allows you to work with materials in a roll, ensures even temperature distribution and much higher efficiency. For this reason, it is the standard in professional sublimation printing.
How to choose industrial sublimation calenders?
The choice of a sublimation calender should be based on the analysis of the entire production line. Key parameters are:
- Working width matched to sublimation printer
- Temperature stability of the heating shaft
- Adjusting the material transport speed
- Uniform pressure over the entire surface
- Possibility of integration with textile production
The calender must be performance-matched to the printer. Improper balancing causes downtime and limits production scalability.
Diferro Calenders from The Color Company
The Color Company offers, as an authorized distributor, Diferro calenders designed for professional textile sublimation.
Diferro calenders offer precise temperature control, a stable industrial design and the possibility of continuous operation. They are designed for companies that own sublimation printers and want to develop production without compromising on quality.
Summary
Sublimation calendars are a key component of professional sublimation printing, but their effectiveness depends on the entire process. A sublimation printer, transfer paper, ink and a suitable calender form a coherent production system.
Investing in an industrial sublimation calender is a strategic decision that directly affects the quality, efficiency and profitability of production.
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