Survey on dyeing faults

Southeast University KNIT DYEING YARN DYEING WOVEN DYEING Prepared By : Mazadul Hasan sheshir ID: 2010000400008 13 th Batch (session 2009-2013) Department : Wet Processing Technology Email: mazadulhasan@yahoo.com Blog : www. Textilelab.blogspot.com (visit) Southeast University Department Of Textile Engineering I/A 251,252 Tejgaon Dhaka Bangladesh Prepared By : Faults in Dyeing Sector Faults in Dyeing Sector Yarn Dyeing Faults 1. Package un-level 2. Package to package shade variation 3. Color spot 4. Ring mark 5. Dirt mark Yarn Dyein g Fault 1. Package Unlevel Causes: a. Tension variation while soft winding of the package b. Lot mixing of yarns in the same package c. Different counts of yarns in the same package d. Pressure variation in the machine vessel e. Improper pretreatment of the yarn f. Improper quality of the dyes and chemicals g. Improper acid treatment after scouring and bleaching 2. Package to Package shade variation Causes: a. Improper setting of yarn packages in the machine b. Lot mixing of the packages c. Count variation of packages Causes: a. Improper setting of yarn packages in the machine b. Lot mixing of the packages c. Count variation of packages Packag e Unlevel 3. Color Spot Causes: a. Floating of dye particles in the air b. Improper per-oxide killing c. Hardness of water d. Improper mixing of dyestuffs Packag e Unlevel P 2 P shade variatio n 5. Ring Mark Causes: a. Improper drying of the packages b. Improper peroxide killing 4. Dirt Mark Causes: a. Dirty handling of the packages b. Presence of dust in the air Figure: Dirt mark Packag e Unlevel P 2 P shade variatio n Colo r Spot Woven Dyeing Faults 1. White spot 2. Color spot 3. Bug spot 4. Water mark 5. Crease mark 6. Long stripe 7. Uneven shade 8. Running shade 9. Listing effect 10. Dirty mark 11. Oil spot 12. Stop mark Woven Dyeing Fault Woven Dyeing Fault 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 Causes: a. Foreign particles present on fabric before dyeing b. Foreign particles present in the solution c. Hairiness present in fabric from brushing 1. White Spot 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 [...]... bath (i.e dye bath, chemical bath, washing bath) 2 Falling of insects on the fabric during dyeing 12 Stop mark Cause: Stopping of machine unexpectedly during processing Figure: Water Mark Knit Dyeing Faults 1 Uneven Dyeing 2 Shade variation i) Roll to roll shade variation ii) Batch to batch shade variation iii) Continuous shade variation in a roll (Running shade/Tailing effect/Ending effect) iv) Side... Dye spots 5 Soda spots 6 Hole 1 Uneven Dyeing Causes: i) If uneven pretreatment is done, absorbency and whiteness of fabric will be different at different places and consequently uneven dyeing will occurred ii) Very rapid addition of dyes and chemicals iii) Lack of controlling dyeing machine like- Machine speed - Temperature of the process - Dosing time - Circulation pump and reel speed - Plaiting device... to crease mark formation - Faulty plaiting device - Variation of heating & cooling rate - Improper fabric movement - For 100% cotton, if GSM>180, unbalanced structure, presence of lycra, not properly heat set increase the tendency to crease mark formation 4 Dye Spot Causes: i.Operator negligence ii.Dye bath hardness iii.Improper Agitation of dyestuff iv.Dye molecule deposition on the fabric Causes:... ratio - Improper washing after dyeing 2 Shade Variation 2.1 Roll to roll shade variation Causes: i) Not equal rope length in each chamber Then cycle time will vary if reel speed will same and shade variation occur ii) Not equal flow speed in each nozzle Then cycle time will vary if length of each roll will same and shade variation occur 2.2 Batch to Batch shade variation Causes: i) Different batches... Dispersion or Solubility Properties b Unstable chemicals c Silicones in the dye bath d Alkali residues in the goods e Presence of iron 2 Improper Washing 3 Operator negligence 10 10 11 11 12 12 11 22 33 44 55 66 77 88 99 3 Crease Mark Causes: a.Lack of balance in construction of the fabric b.Pressure of padder roller c.Direct Heating or Shock cooling 10 10 11 11 12 12 11 22 33 44 55 66 77 88 4 Long Stripe... lot, chemicals, dyeing procedure, temperature are different for each batch iv) Low quality water especially PH, hardness and sodium carbonate content 2.3 Running shade Causes: - Machine over-loading - Running at lower nozzle pressure - High bath draining temperature - Improper cycle time - Improper length of rope Causes: - More cycle time, more time fabric will be in folded condition increase tendency... deposition on the fabric Causes: 1.Soaping start before wash 2.CaCO3 or MgCO3 in soaping bath 6 Hole 6 Hole Causes: 1 Dye bath water hardness 2 Deposition of ferrous or ferric ion on the fabric surface 3 Defective plaiting device of the machine Problem of dyeing a Problem of shade matching Causes: 1 2 3 4 Dye factor Process factor Machine factor Man factor b Fastness problem Properties of Dyes & Chemicals... Improper mercerization d Low solubility of dyes & chemicals e Negligence of operators to solubilize dyes and chemicals 11 11 12 12 11 22 33 44 55 66 77 88 99 10 10 6 Running Shade Causes: a Change in pick-up percentage along the length of the fabric b Improper fabric Speed 11 11 12 12 11 22 33 44 55 66 77 88 99 10 10 11 11 12 12 7 Listing Effect Causes: a Improper padder pressure in different zones of padder... pressure in different zones of padder roller (left, middle & right zone) b Worn out squeeze roller 11 8 Dirt Spot Causes: 22 33 Presence of Dirt in the air Dirty handling of the fabric 44 55 66 77 88 99 10 10 11 11 9 Oil spot Cause: Oil dropped on the fabric 12 12 11 22 33 44 55 66 77 88 99 1 0 1 1 1 2 10 Water Mark Cause: Water is dropped on the fabric after final drying 11 Bug Spot Causes: 1 Insect present... http://www.facebook.com/pages/Garments-Manufacturing-Technology/472364799463126 3 Wet processing Technology Link : http://www.facebook.com/pages/Wet-Processing-Technology -Dyeing- /468645219825404 4 Fashion-Design-and-Technology Link : http://www.facebook.com/pages/Fashion-Design-and-Technology/587655294583875?ref=ts&fref=ts . Engineering I/A 251,252 Tejgaon Dhaka Bangladesh Prepared By : Faults in Dyeing Sector Faults in Dyeing Sector Yarn Dyeing Faults 1. Package un-level 2. Package to package shade variation 3. Color spot. of insects on the fabric during dyeing. 10. Water Mark Cause: Water is dropped on the fabric after final drying. 1. Uneven Dyeing. 2. Shade variation. i) Roll to roll shade variation. ii) Batch. Hole Knit Dyeing Faults 1. Uneven Dyeing Causes: i) If uneven pretreatment is done, absorbency and whiteness of fabric will be different at different places and consequently uneven dyeing will