Knit dyeing faults and remedies

Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 1 KNIT DYEING FAULTS AND REMEDIES Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 1 KNIT DYEING FAULTS AND REMEDIES Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 1 KNIT DYEING FAULTS AND REMEDIES Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 2 Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 2 Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 2 Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 3 Letter of Transmittal To Rajib Shaha Assistant Professor Department of Textile Engineering Southeast University Subject: submission of Project Report on “Knit dyeing faults & remedies”. Sir, With due respect & humble, we are the students of Department of Textile Engineering, Southeast University have been successfully concluded our project. In this stage we are submitting our Project Report on “Knit dyeing faults & remedies” as a part of our B.Sc. in Textile Engineering requirement that bears three (03) credit hours under your supervision. We therefore request and expect that, you will appreciate us with any sort of recommendations and valued suggestions & will cordially receive this Project Report for your kind assessment. Sincerely Yours, Ariful Islam ID: 2010000400005 Mazadul Hasan ID: 2010000400008 Major : Wet Processing Technology Batch: 13 th Department of Textile Engineering Southeast University Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 3 Letter of Transmittal To Rajib Shaha Assistant Professor Department of Textile Engineering Southeast University Subject: submission of Project Report on “Knit dyeing faults & remedies”. Sir, With due respect & humble, we are the students of Department of Textile Engineering, Southeast University have been successfully concluded our project. In this stage we are submitting our Project Report on “Knit dyeing faults & remedies” as a part of our B.Sc. in Textile Engineering requirement that bears three (03) credit hours under your supervision. We therefore request and expect that, you will appreciate us with any sort of recommendations and valued suggestions & will cordially receive this Project Report for your kind assessment. Sincerely Yours, Ariful Islam ID: 2010000400005 Mazadul Hasan ID: 2010000400008 Major : Wet Processing Technology Batch: 13 th Department of Textile Engineering Southeast University Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 3 Letter of Transmittal To Rajib Shaha Assistant Professor Department of Textile Engineering Southeast University Subject: submission of Project Report on “Knit dyeing faults & remedies”. Sir, With due respect & humble, we are the students of Department of Textile Engineering, Southeast University have been successfully concluded our project. In this stage we are submitting our Project Report on “Knit dyeing faults & remedies” as a part of our B.Sc. in Textile Engineering requirement that bears three (03) credit hours under your supervision. We therefore request and expect that, you will appreciate us with any sort of recommendations and valued suggestions & will cordially receive this Project Report for your kind assessment. Sincerely Yours, Ariful Islam ID: 2010000400005 Mazadul Hasan ID: 2010000400008 Major : Wet Processing Technology Batch: 13 th Department of Textile Engineering Southeast University Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 4 Supervising Faculty’s Approval SOUTHEAST UNIVERSITY Department of Textile Engineering ……………………………………………………………… Rajib Shaha Assistant Professor Department of Textile Engineering Southeast University I/A 251, 252 Tejgaon, Dhaka Cell No.: 01726419580 Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 4 Supervising Faculty’s Approval SOUTHEAST UNIVERSITY Department of Textile Engineering ……………………………………………………………… Rajib Shaha Assistant Professor Department of Textile Engineering Southeast University I/A 251, 252 Tejgaon, Dhaka Cell No.: 01726419580 Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 4 Supervising Faculty’s Approval SOUTHEAST UNIVERSITY Department of Textile Engineering ……………………………………………………………… Rajib Shaha Assistant Professor Department of Textile Engineering Southeast University I/A 251, 252 Tejgaon, Dhaka Cell No.: 01726419580 Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 5 ACKNOWLEDGEMENT At first my gratefulness goes to Almighty Allah to give me strength and ability to complete the industrial training and this report. May your name be exalted, honored and glorified. Industrial Attachment Course is an academic function of the College of Textile Technology. We are highly delighted to express our regards & gratitude to honorable Principal Prof. Syed Fakhrul Hassan.for providing us the chance to complete our Industrial Attachment with Knit Concern Ltd. Special thanks to our supervising teacher, Rajib Shaha to whom I am extremely indebted for his tremendous support and guidance throughout my training period, without whose help it would not have been possible to complete the training successfully. We also take the opportunity to express our sincerest gratitude to the management, administration & personnel of Knit Concern Ltd. for their kind assistance. Heartfelt thanks goes to Engr. A. K. M Mohsin Ahmed, General Manager, Knit Dyeing, Knit Concern Ltd. and Mr. Khalid Masud, CEO & GM, Yarn dyeing, Knit Concern ltd. for their permission & excellent cooperation during the period of our training. We would also like to thank Mr. Touhidul Islam Kakon (Dyeing Manager, Knit) & Mr. Zahid Arman (Dyeing Manager, Yarn) for their sincere support. The generous support is greatly appreciated. I would also like to thank Production Officers, Senior Production Officer and other officials of Knit Concern Ltd. for helping me to complete industrial training successfully. our gratitude also goes to all the employees of Knit Concern Ltd. for their sincere co- operation, support and valuable advices. Above all, we would like to acknowledge our deep debt to all teachers of our college & particularly of Wet Processing Department for their kind inspiration & help, which remain as the backdrop of all our efforts. Finally, we would like to acknowledge that we remain responsible for the inadequacies & errors, which doubtless remain in the following report. Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 5 ACKNOWLEDGEMENT At first my gratefulness goes to Almighty Allah to give me strength and ability to complete the industrial training and this report. May your name be exalted, honored and glorified. Industrial Attachment Course is an academic function of the College of Textile Technology. We are highly delighted to express our regards & gratitude to honorable Principal Prof. Syed Fakhrul Hassan.for providing us the chance to complete our Industrial Attachment with Knit Concern Ltd. Special thanks to our supervising teacher, Rajib Shaha to whom I am extremely indebted for his tremendous support and guidance throughout my training period, without whose help it would not have been possible to complete the training successfully. We also take the opportunity to express our sincerest gratitude to the management, administration & personnel of Knit Concern Ltd. for their kind assistance. Heartfelt thanks goes to Engr. A. K. M Mohsin Ahmed, General Manager, Knit Dyeing, Knit Concern Ltd. and Mr. Khalid Masud, CEO & GM, Yarn dyeing, Knit Concern ltd. for their permission & excellent cooperation during the period of our training. We would also like to thank Mr. Touhidul Islam Kakon (Dyeing Manager, Knit) & Mr. Zahid Arman (Dyeing Manager, Yarn) for their sincere support. The generous support is greatly appreciated. I would also like to thank Production Officers, Senior Production Officer and other officials of Knit Concern Ltd. for helping me to complete industrial training successfully. our gratitude also goes to all the employees of Knit Concern Ltd. for their sincere co- operation, support and valuable advices. Above all, we would like to acknowledge our deep debt to all teachers of our college & particularly of Wet Processing Department for their kind inspiration & help, which remain as the backdrop of all our efforts. Finally, we would like to acknowledge that we remain responsible for the inadequacies & errors, which doubtless remain in the following report. Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 5 ACKNOWLEDGEMENT At first my gratefulness goes to Almighty Allah to give me strength and ability to complete the industrial training and this report. May your name be exalted, honored and glorified. Industrial Attachment Course is an academic function of the College of Textile Technology. We are highly delighted to express our regards & gratitude to honorable Principal Prof. Syed Fakhrul Hassan.for providing us the chance to complete our Industrial Attachment with Knit Concern Ltd. Special thanks to our supervising teacher, Rajib Shaha to whom I am extremely indebted for his tremendous support and guidance throughout my training period, without whose help it would not have been possible to complete the training successfully. We also take the opportunity to express our sincerest gratitude to the management, administration & personnel of Knit Concern Ltd. for their kind assistance. Heartfelt thanks goes to Engr. A. K. M Mohsin Ahmed, General Manager, Knit Dyeing, Knit Concern Ltd. and Mr. Khalid Masud, CEO & GM, Yarn dyeing, Knit Concern ltd. for their permission & excellent cooperation during the period of our training. We would also like to thank Mr. Touhidul Islam Kakon (Dyeing Manager, Knit) & Mr. Zahid Arman (Dyeing Manager, Yarn) for their sincere support. The generous support is greatly appreciated. I would also like to thank Production Officers, Senior Production Officer and other officials of Knit Concern Ltd. for helping me to complete industrial training successfully. our gratitude also goes to all the employees of Knit Concern Ltd. for their sincere co- operation, support and valuable advices. Above all, we would like to acknowledge our deep debt to all teachers of our college & particularly of Wet Processing Department for their kind inspiration & help, which remain as the backdrop of all our efforts. Finally, we would like to acknowledge that we remain responsible for the inadequacies & errors, which doubtless remain in the following report. Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 6 Abstract As a part of the B. Sc. in Textile Engineering, we have completed our Project titled “Knit Dyeing faults and Remedies ”. We try to focus on the different types of knit Dyeing Faults. We divided it into the pre treatment faults, Dyeing faults, Finishing Faults. In our literature review We show the dyeing process Finishing Process and We show the all parameters of dyeing and finishing like Pressure , Temperature ,time etc . We Discuss all Process and Parameters, done in the Knit Concern group . We collect all physical sample of fault. We have studied the effect of Knit Dyeing faults any Find out the Remedies of all faults . The art of processing of textiles is not new aspect. As the time passes new processes, methods and machines have been in use to improve the productivity and quality of the processed fabric. In the era of energy and water saving and eco-friendly processing, to maintain the quality and cost has become tough task. It is always found that 70% problems of dyeing are attributed to poor treatment of the fabric. Hence it becomes necessary to give emphasis right from pretreatment to ultimate dyeing steps to achieve best quality dyed goods. "RIGHT FIRST TIME AND ALL THE TIME RIGHT" dyeing quality can be easily achieved by strictly adhering to process control parameters of each and every step of fabric processing. [1] In this paper an attempt has been made to highlight the various problems encountered due to men, machine and other factors of processing for damage about the possible causes and remedies of these dyeing problems helps the processes as a ready recockener for avoiding these problems. Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 6 Abstract As a part of the B. Sc. in Textile Engineering, we have completed our Project titled “Knit Dyeing faults and Remedies ”. We try to focus on the different types of knit Dyeing Faults. We divided it into the pre treatment faults, Dyeing faults, Finishing Faults. In our literature review We show the dyeing process Finishing Process and We show the all parameters of dyeing and finishing like Pressure , Temperature ,time etc . We Discuss all Process and Parameters, done in the Knit Concern group . We collect all physical sample of fault. We have studied the effect of Knit Dyeing faults any Find out the Remedies of all faults . The art of processing of textiles is not new aspect. As the time passes new processes, methods and machines have been in use to improve the productivity and quality of the processed fabric. In the era of energy and water saving and eco-friendly processing, to maintain the quality and cost has become tough task. It is always found that 70% problems of dyeing are attributed to poor treatment of the fabric. Hence it becomes necessary to give emphasis right from pretreatment to ultimate dyeing steps to achieve best quality dyed goods. "RIGHT FIRST TIME AND ALL THE TIME RIGHT" dyeing quality can be easily achieved by strictly adhering to process control parameters of each and every step of fabric processing. [1] In this paper an attempt has been made to highlight the various problems encountered due to men, machine and other factors of processing for damage about the possible causes and remedies of these dyeing problems helps the processes as a ready recockener for avoiding these problems. Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 6 Abstract As a part of the B. Sc. in Textile Engineering, we have completed our Project titled “Knit Dyeing faults and Remedies ”. We try to focus on the different types of knit Dyeing Faults. We divided it into the pre treatment faults, Dyeing faults, Finishing Faults. In our literature review We show the dyeing process Finishing Process and We show the all parameters of dyeing and finishing like Pressure , Temperature ,time etc . We Discuss all Process and Parameters, done in the Knit Concern group . We collect all physical sample of fault. We have studied the effect of Knit Dyeing faults any Find out the Remedies of all faults . The art of processing of textiles is not new aspect. As the time passes new processes, methods and machines have been in use to improve the productivity and quality of the processed fabric. In the era of energy and water saving and eco-friendly processing, to maintain the quality and cost has become tough task. It is always found that 70% problems of dyeing are attributed to poor treatment of the fabric. Hence it becomes necessary to give emphasis right from pretreatment to ultimate dyeing steps to achieve best quality dyed goods. "RIGHT FIRST TIME AND ALL THE TIME RIGHT" dyeing quality can be easily achieved by strictly adhering to process control parameters of each and every step of fabric processing. [1] In this paper an attempt has been made to highlight the various problems encountered due to men, machine and other factors of processing for damage about the possible causes and remedies of these dyeing problems helps the processes as a ready recockener for avoiding these problems. Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 7 Project Description: The study was intended on the topic, ‘Knit dyeing Faults and Remedies’ which carry out a great importance on the textile sector. Textile and confection sector is one of the leading fields of socio- economical activity, regarding its technological state, economical efficiency and social interaction. Marketing conditions became harder within the recent years of 2000, urging this crucial sector for the economy to aim taking new and radical measures and bounding it to determine the quality. Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 7 Project Description: The study was intended on the topic, ‘Knit dyeing Faults and Remedies’ which carry out a great importance on the textile sector. Textile and confection sector is one of the leading fields of socio- economical activity, regarding its technological state, economical efficiency and social interaction. Marketing conditions became harder within the recent years of 2000, urging this crucial sector for the economy to aim taking new and radical measures and bounding it to determine the quality. Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 7 Project Description: The study was intended on the topic, ‘Knit dyeing Faults and Remedies’ which carry out a great importance on the textile sector. Textile and confection sector is one of the leading fields of socio- economical activity, regarding its technological state, economical efficiency and social interaction. Marketing conditions became harder within the recent years of 2000, urging this crucial sector for the economy to aim taking new and radical measures and bounding it to determine the quality. Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 8 Origin of the report Name of the factory: KNIT CONCERN LIMITED Type : 100 % Export Oriented Composite knitwear Industry Year of Establishment : 1998 Status ( Legal Structure ) : Private Limited Company Annual Production capacity : 10000 ton of knit fabric ( Open & tubular form ) Total Manpower: Around 8000 Address : 62 ,Water Works Road, Godnail.Narayanganj, Bangladesh. Telephone Number : +88 – 02 - 7641086 Fax Number : + 88 – 02 – 7641087 URL : http://www.knitconcern.com location of KCL: Knit Concern Limited is located at Godnail , in Narayanganj about 18 km from the EPZ. Knit Dyeing Section: It has two section of knit dyeing floor – KCL (Old floor) & KCA (New floor). Each contains around 100 thousands square ft area. Production capacity: approximately 50 ton/day Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 8 Origin of the report Name of the factory: KNIT CONCERN LIMITED Type : 100 % Export Oriented Composite knitwear Industry Year of Establishment : 1998 Status ( Legal Structure ) : Private Limited Company Annual Production capacity : 10000 ton of knit fabric ( Open & tubular form ) Total Manpower: Around 8000 Address : 62 ,Water Works Road, Godnail.Narayanganj, Bangladesh. Telephone Number : +88 – 02 - 7641086 Fax Number : + 88 – 02 – 7641087 URL : http://www.knitconcern.com location of KCL: Knit Concern Limited is located at Godnail , in Narayanganj about 18 km from the EPZ. Knit Dyeing Section: It has two section of knit dyeing floor – KCL (Old floor) & KCA (New floor). Each contains around 100 thousands square ft area. Production capacity: approximately 50 ton/day Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 8 Origin of the report Name of the factory: KNIT CONCERN LIMITED Type : 100 % Export Oriented Composite knitwear Industry Year of Establishment : 1998 Status ( Legal Structure ) : Private Limited Company Annual Production capacity : 10000 ton of knit fabric ( Open & tubular form ) Total Manpower: Around 8000 Address : 62 ,Water Works Road, Godnail.Narayanganj, Bangladesh. Telephone Number : +88 – 02 - 7641086 Fax Number : + 88 – 02 – 7641087 URL : http://www.knitconcern.com location of KCL: Knit Concern Limited is located at Godnail , in Narayanganj about 18 km from the EPZ. Knit Dyeing Section: It has two section of knit dyeing floor – KCL (Old floor) & KCA (New floor). Each contains around 100 thousands square ft area. Production capacity: approximately 50 ton/day Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 9 CONTENTS Page No. Acknowledgement……………………………………………………………… 3 Abstract…………………………………………………………………………………………………………………… 4 Project Description…………………………………………………………………………………………………….5 Origin of the report……………………………………………………………………………………………………6 1. INTRODUCTION………………………………………………………………………………………………… 8 2. PROJECT OBJECTIVE ……………………………………………………………………………………………9 3. LITURATURE REVIEW: 3.1. Dyeing Flow Chart ……………………………………………………… 11 3.2 SCOURING PROCESS… 12 3.3 Special Process: Deminelilazation Hot …………………………………………………………….13 3.4 Dyeing : …………………………………………………………………………………………………………… 14 3.5 Finishing …………………………………………………………………………………………………………… 14 3.7 DEFECT ………… ………………………………………………………………………………………………… 13-15 3.7.1 Defination Of Fault ……………………………………………………………………………….15-16 3.7.4 Dyeing Faults…………………………………………………………………………………………17 3.7.4 Types of Dyeing Faults ……………………………………………………………………… 18-19 4 . EXPERIMANTAL DATA 4.6 Yarn ………… ……………………………………………………………………………………………………… 20 4.7 Grey Fabrics ………… ……………………………………………………………………………………………20 4.8 Chemical list ………… ……………………………………………………………………………………………21 4.9 Dyes list………… ………………………………………………………………………………………………… 22-23 4.4 Knit Dyeing Operation process : ……………………………………………………………………………24 4.6 Inspection of Grey Fabric from knitting section to Dyeing: ……………………………………24-25 4.5 Production parameters: …………………………………………………………………………………………25 4.7Parameters of dyeing & Finishing M/C: …………………………………………………………………25-29 5. ANALYSIS DATA 5.1 Grey Fabric faults ……………………………………………………………………………………………… 31-34 5.2 Pre Treatment faults ……………………………………………………………………………………………35-39 5.3 Optical brightener fault…………………………………………………………………………………………40-42 5.3 Finishing Faults …………………………………………………………………………………………………… 43-49 5.4 Dyeing Faults………………………………………………………………………………………………………….50-63 6.RESULT & DISCUSSION ………………………………………………………………………………………………66-74 CONCLUTION REFIRANCE THANKS Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 9 CONTENTS Page No. Acknowledgement……………………………………………………………… 3 Abstract…………………………………………………………………………………………………………………… 4 Project Description…………………………………………………………………………………………………….5 Origin of the report……………………………………………………………………………………………………6 1. INTRODUCTION………………………………………………………………………………………………… 8 2. PROJECT OBJECTIVE ……………………………………………………………………………………………9 3. LITURATURE REVIEW: 3.1. Dyeing Flow Chart ……………………………………………………… 11 3.2 SCOURING PROCESS… 12 3.3 Special Process: Deminelilazation Hot …………………………………………………………….13 3.4 Dyeing : …………………………………………………………………………………………………………… 14 3.5 Finishing …………………………………………………………………………………………………………… 14 3.7 DEFECT ………… ………………………………………………………………………………………………… 13-15 3.7.1 Defination Of Fault ……………………………………………………………………………….15-16 3.7.4 Dyeing Faults…………………………………………………………………………………………17 3.7.4 Types of Dyeing Faults ……………………………………………………………………… 18-19 4 . EXPERIMANTAL DATA 4.6 Yarn ………… ……………………………………………………………………………………………………… 20 4.7 Grey Fabrics ………… ……………………………………………………………………………………………20 4.8 Chemical list ………… ……………………………………………………………………………………………21 4.9 Dyes list………… ………………………………………………………………………………………………… 22-23 4.4 Knit Dyeing Operation process : ……………………………………………………………………………24 4.6 Inspection of Grey Fabric from knitting section to Dyeing: ……………………………………24-25 4.5 Production parameters: …………………………………………………………………………………………25 4.7Parameters of dyeing & Finishing M/C: …………………………………………………………………25-29 5. ANALYSIS DATA 5.1 Grey Fabric faults ……………………………………………………………………………………………… 31-34 5.2 Pre Treatment faults ……………………………………………………………………………………………35-39 5.3 Optical brightener fault…………………………………………………………………………………………40-42 5.3 Finishing Faults …………………………………………………………………………………………………… 43-49 5.4 Dyeing Faults………………………………………………………………………………………………………….50-63 6.RESULT & DISCUSSION ………………………………………………………………………………………………66-74 CONCLUTION REFIRANCE THANKS Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 9 CONTENTS Page No. Acknowledgement……………………………………………………………… 3 Abstract…………………………………………………………………………………………………………………… 4 Project Description…………………………………………………………………………………………………….5 Origin of the report……………………………………………………………………………………………………6 1. INTRODUCTION………………………………………………………………………………………………… 8 2. PROJECT OBJECTIVE ……………………………………………………………………………………………9 3. LITURATURE REVIEW: 3.1. Dyeing Flow Chart ……………………………………………………… 11 3.2 SCOURING PROCESS… 12 3.3 Special Process: Deminelilazation Hot …………………………………………………………….13 3.4 Dyeing : …………………………………………………………………………………………………………… 14 3.5 Finishing …………………………………………………………………………………………………………… 14 3.7 DEFECT ………… ………………………………………………………………………………………………… 13-15 3.7.1 Defination Of Fault ……………………………………………………………………………….15-16 3.7.4 Dyeing Faults…………………………………………………………………………………………17 3.7.4 Types of Dyeing Faults ……………………………………………………………………… 18-19 4 . EXPERIMANTAL DATA 4.6 Yarn ………… ……………………………………………………………………………………………………… 20 4.7 Grey Fabrics ………… ……………………………………………………………………………………………20 4.8 Chemical list ………… ……………………………………………………………………………………………21 4.9 Dyes list………… ………………………………………………………………………………………………… 22-23 4.4 Knit Dyeing Operation process : ……………………………………………………………………………24 4.6 Inspection of Grey Fabric from knitting section to Dyeing: ……………………………………24-25 4.5 Production parameters: …………………………………………………………………………………………25 4.7Parameters of dyeing & Finishing M/C: …………………………………………………………………25-29 5. ANALYSIS DATA 5.1 Grey Fabric faults ……………………………………………………………………………………………… 31-34 5.2 Pre Treatment faults ……………………………………………………………………………………………35-39 5.3 Optical brightener fault…………………………………………………………………………………………40-42 5.3 Finishing Faults …………………………………………………………………………………………………… 43-49 5.4 Dyeing Faults………………………………………………………………………………………………………….50-63 6.RESULT & DISCUSSION ………………………………………………………………………………………………66-74 CONCLUTION REFIRANCE THANKS Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 10 Introduction: The art of processing of textiles today is well known to all processors. In the past the organized sector dominated the textile scene; whereas today the decentralized process houses are predominant. There is a shift in emphasis from the requirements related to finished products to environment related requirements. Requirements related to the finished product fastness & other properties of dyestuffs & chemicals, processing etc. shift of emphasis environment related requirements, cost reduction, security, energy & water saving, toxicology, hygiene legal regulations, and competitiveness. Reduction in costs and utilities are achieved by the trend to telescope processes. In order to be competitive processors would have to give equal if not better quality then the existing material at the same price. Considering the energy and labour costs, the only means of maintaining a competitive edge is to lay emphasis on 'Quality'. Good quality does not necessarily mean increased prices, but in fact would mean "Doing it right the first time" thereby reduce the costs. Thus with this theme in mind of "Doing it right the first time" we would have to first understand the problems in the process of dyeing. So, this paper mainly discusses "Problems in Dyeing & its remedies". The ultimate law of accuracy states, "when working towards a solution of a problem, it always helps if you know the answer provided, of course you know there is problem". Every manufacturing unit has a number of problems, however problem solving cannot be considered to be astrology or palmistry, but it needs the fullest knowledge of basic facts. Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 10 Introduction: The art of processing of textiles today is well known to all processors. In the past the organized sector dominated the textile scene; whereas today the decentralized process houses are predominant. There is a shift in emphasis from the requirements related to finished products to environment related requirements. Requirements related to the finished product fastness & other properties of dyestuffs & chemicals, processing etc. shift of emphasis environment related requirements, cost reduction, security, energy & water saving, toxicology, hygiene legal regulations, and competitiveness. Reduction in costs and utilities are achieved by the trend to telescope processes. In order to be competitive processors would have to give equal if not better quality then the existing material at the same price. Considering the energy and labour costs, the only means of maintaining a competitive edge is to lay emphasis on 'Quality'. Good quality does not necessarily mean increased prices, but in fact would mean "Doing it right the first time" thereby reduce the costs. Thus with this theme in mind of "Doing it right the first time" we would have to first understand the problems in the process of dyeing. So, this paper mainly discusses "Problems in Dyeing & its remedies". The ultimate law of accuracy states, "when working towards a solution of a problem, it always helps if you know the answer provided, of course you know there is problem". Every manufacturing unit has a number of problems, however problem solving cannot be considered to be astrology or palmistry, but it needs the fullest knowledge of basic facts. Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 10 Introduction: The art of processing of textiles today is well known to all processors. In the past the organized sector dominated the textile scene; whereas today the decentralized process houses are predominant. There is a shift in emphasis from the requirements related to finished products to environment related requirements. Requirements related to the finished product fastness & other properties of dyestuffs & chemicals, processing etc. shift of emphasis environment related requirements, cost reduction, security, energy & water saving, toxicology, hygiene legal regulations, and competitiveness. Reduction in costs and utilities are achieved by the trend to telescope processes. In order to be competitive processors would have to give equal if not better quality then the existing material at the same price. Considering the energy and labour costs, the only means of maintaining a competitive edge is to lay emphasis on 'Quality'. Good quality does not necessarily mean increased prices, but in fact would mean "Doing it right the first time" thereby reduce the costs. Thus with this theme in mind of "Doing it right the first time" we would have to first understand the problems in the process of dyeing. So, this paper mainly discusses "Problems in Dyeing & its remedies". The ultimate law of accuracy states, "when working towards a solution of a problem, it always helps if you know the answer provided, of course you know there is problem". Every manufacturing unit has a number of problems, however problem solving cannot be considered to be astrology or palmistry, but it needs the fullest knowledge of basic facts. [...]... broken yarns DYEING FAULTS: The faults which are visible after dyeing are called Dyeing faults These faults descries the quality of the fabrics So to overcome from this faults we have to know the causes and the remedies of these dyeing faults TYPES OF FAULTS Dyeing faults can be described on the following basic things 1 Unlevelness ( due to dyeing conditions ) i Ending problems ii Cloudy dyeing iii... filter and clean before dyeing and pretreatment Knit Dyeing and and Pretreatment machine for scouring and bleaching At Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 35 Southeast University Department of Textile Problem: Oil marks on fabrics Sources & Causes:  If the fabric is stored for more than a week,it may oxidise depending on the quality of knitting... matted balls on the surface of knitted fabrics Pilling occurs when soft yarn rubs against itself, resulting in tangled fibers and produces an uneven and worn look Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 19 Southeast University Department of Textile CHAPTER – 4 Experimental Data Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 20 Southeast University... restricting the production, generating proper solutions and implement them in a proper way Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 11 Southeast University Department of Textile CHAPTER - 3 LITURATURE REVIEW Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 12 Southeast University Department of Textile 3.1 Dyeing Flow Chart: Gray Fabric Inspection Senging... Industry : Knit Concern Group Over feed 140 150 110 110 110 110 Speed m/min 14 20 12 15 7 9 110 110 130 9 10 10 80% 80% 80% 80% 80% 60% 80% 80% 80% | Project : Knit Dyeing Faults and Remedies 29 Southeast University Department of Textile CHAPTER -3 DATA ANALYSIS Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 30 Southeast University Department of Textile Gray Fabric Faults Fault... Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 14 Southeast University Department of Textile 3.4 Dyeing : The dyeing aim is to colour the textile material in a uniform way These two stages of the process are performed more often on Woven fabric or knit, however those can be also performed on fibre, thread or on some clothing Types of dyeing e work for 1 Knit Dyeing 2 Yarn Dyeing. .. Import& Export | Project : Knit Dyeing Faults and Remedies 23 Southeast University Department of Textile Inspection of Grey Fabric from knitting section to Dyeing:  Checking flow-chart – Knitted fabric (checked in knitting section) Grey fabric inspection section for checking by dyeing dept Checking Ok Not ok To storage/ batch section Dyeing Recheck If not ok, Rejection Checking Standard: Varies depending... Light Shade ) 20 Stripping (If Color not Ok) Production parameters of Knit Dyeing : a pH: During H2O2 bleaching pH 9 – 11 During reactive dyeing pH 10.5 – 12 During disperse dyeing pH 4.5 – 5.5 During Leveling pH 5.5 – 6.0 During Salt pH 6.0 – 6.5 During Soda pH 10.5-11.5 Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 25 Southeast University Department of Textile b Temperature:... 600-700C For cotton dyeing 800-900C ( For hot brand ) For cotton dyeing 600C ( For Medium brand ) 0 For cotton dyeing 80 C ( For Turquoise/ Blue RSPCL/CNR ) 0 Polyester dyeing: 100 -1300C For scouring 60-90 mins For reactive dyeing 60-90 mins For disperse dyeing 60-90 mins For Enzyme treatment 60-90 mins d M:L ratio: For reactive dyeing M:L ration maintained 1 : 3 ( polyester - Airflow Dyeing ) 1 : 4 (... well as proper oiling Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 33 Southeast University Department of Textile Fault Name Fly Yarn contamination Cause In knitting section too much lint is flying to and fro that are created from yarn due to low twist as well as yarn friction This lint may adhere or attaches to the fabric surface tightly during knit fabric production 1 If yarn . Dyeing Faults and Remedies 1 KNIT DYEING FAULTS AND REMEDIES Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 1 KNIT DYEING FAULTS. : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 1 KNIT DYEING FAULTS AND REMEDIES Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing. Concern Group | Project : Knit Dyeing Faults and Remedies 2 Southeast University Department of Textile Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 2 Southeast University