Knit Dyeing FaultsPresentation Transcript

1. Prepared By : Prepared By : Mazadul Hasan sheshir ID: 2010000400008 13th Batch Wet
Processing Technology Email: mazadulhasan@yahoo.com Southeast University Southeast
University Department Of Textile Engineering I/A 251,252 Tejgaon Dhaka Bangladesh
2. Oil and grease stains Causes: 1. Inferior quality of oil used in Knitting 2. Excess oiling during knitting
3. Inferior quality of detergent used in pretreatment 4. Poor emulsification in case of excessive oil in
fabric 5. Improper washing 6. Not maintaining the critical temperature in respect of emulsification
Remedies: Emulsifiers are used to remove oil and grease stains.
3. Rope Marks Causes: When scouring and bleaching the cloth in rope form under high pressure
during mangling, folds develop longitudinally. Remedies: In order to remove the folds, cloth is
stentered and in case of severe folds it is mercerized.
4. Poor Scouring Causes: When chemical, temperature,PH, time are not properly maintain then this
fault is form. Remedies: Properly control chemical, temperature, PH, time.
5. Uneven Dyeing Causes: 1. Uneven pretreatment (uneven scouring & bleaching). 2. Improper color
dosing. 3. Using dyes of high fixation property. 4. Uneven heat-setting in case of synthetic fibers. 5.
Lack of control on dyeing m/c Remedies: 1. By ensuring even pretreatment. 2. By ensuring even
heat-setting in case of synthetic fibers. 3. Proper dosing of dyes and chemicals. 4. Proper controlling
of dyeing m/c
6. Dye Stains Causes: Dark selvedges are caused by non-uniform winding of cloth during dyeing on
jiggers. Bronzing effect also appears during dyeing in open jiggers with vat and sulfur dyes.
Remedies: In case of vat and fast colors cloth should be stripped of color and re-dyed. Boiling
leveling bath should be used for direct dyed cloth. Leveling agents should also be added.
7. Lycra burn Causes: Improper mixing of solution. Remedies: Proper mixing of solution.
8. Shade Variation Causes: It refers to color that exactly doesnt match the standard of the prepared
sample. Remedies: This may be due to faulty dye foundation or application or may be due to
variation in dye lot.
9. Hole (Dyeing) Causes: Due to problematic nozzle in dyeing m/c some holes may produce in fabric
during dyeing. Remedies: Nozzles must be cleaned time to time & maintenance should be done
properly.
10. Barre Effect Causes: Basic difference in the polyester component particularly when using textured
filament weft. Remedies: Take appropriate preventive measure to avoid mix up of weft.
11. Chemical stains Chemical spot observed on the fabric.
12. Color Bleeding Causes: It's a loss of color when the dyed fabric is wetted or emerged in water. The
water here, becomes colored and may cause discoloration] of other fabrics. This is usually due to
either improper dye selection or poor dye fastness. Remedies: This problem can be minimizing by
correct dyes and chemical selection.
13. Poor preparationPoor preparation Undissolved chemicals Fabric wet before dyeing Marks or
contamination on padder bowls Condensation drips from roof Resist Spots These show as areas
where the dyestuff has not taken to the fabric
14. Moire Effect (Stenter/ Compactor) Causes: Too high tension during batching and inadequate heat
setting. Remedies: Proper tension during bathing & poor heat setting of fabric prior to dyeing.
15. Crease Marks (Hydro extractor) Causes : Damp fabric moving at high speed in twisted form, in the
Hydro extractor (Centrifuge) Remedies: Use anti Crease, during the Scouring & the Dyeing process
(The use of anti-Crease, swells the Cellulose & prevents the formation of Crease marks) Spread
the fabric in loose & open form & not in the rope form, in the Hydro Extractor.
16. Pin Marks ( Stenter ) Poorly adjusted stenter pin
17. Skewing (Compacting/ Stenter) Fabric Wales appear in the diagonal direction, to the edges of the
fabric, instead of being parallel. Causes : Improper feeding of the fabric, while Calendaring &
Compacting. Remedies: Keep a slit line on one side of the tubular fabric. Use the slit line, as a
reference line, to keep the grain lines straight, while feeding the fabric slowly, on the Calendar, or the
Compactor machines.
18. Surface Hairiness & Piling(Tumble Dryer) Causes : Abrasion due to the contact with rough surfaces
Excessive surface hairiness caused, due to the abrasive tumbling action(Fabric friction in the
Tumble Dryer) Rough Dyeing process & abrasive machine surfaces (Soft Flow Machine tubes,
Tumble Dryer drum etc.) Reprocessing of the fabric is, also a major cause of piling. Remedies:
Avoid using the Tumble Dryer. (Control shrinkage by maximum fabric relaxation & over feed in the
processing) Regularly inspect the fabric contact points on all the machines, for any rough & sharp
surfaces.
19. Lustre (Compacting) Causes : Physical change in fiber due to local pressure and high temperature
on material Excessive setting Remedies: Avoid prolonged contact of stationary material with the
hot machine Select suitable setting temperature
20. Spirality (Washing) Spirality appears in the form of a twisted garment, after washing. The seams on
both the sides of the garment displace, from their position & appear on the front & back of the
garment.
21. Bowing ( Compacting/ Stenter ) Bowing appears as, rows of courses or yarn dyed stripes, forming a
bow shape, along the fabric width. Causes : Uneven distribution of tensions, across the fabric width
while, dyeing or finishing the fabric. Remedies: Bowing can be corrected, by reprocessing the fabric,
by feeding it from the opposite end. A special machine (MAHLO) is also available for, correcting the
bowing in the knitted fabrics.
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