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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 .
Faults in Dyeing SectorFaults in Dyeing Sector
Knit Dyeing Faults
1. Dyeing Hole2. Running Shade 3. Dye Spot4. Uneven shade 5.Batch To Batch shade Variation 6.Roll to roll shade Variation7. Crease Mark8.Softener mark 9.Soda Spot 10.Oil Spot 11.White Spot
Knit Dyeing Fault
Knit Dyeing Fault
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Causes:1. Dye bath water hardness. 2. Deposition of ferrous or ferric ion on the fabric surface 3. Defective plaiting device of the machine.
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Causes:
I.Change in pick-up percentage along the length of the
fabric .
II.Improper fabric Speed.
III.Machine over-loading.
IV.Running at lower nozzle pressure .
V.High bath draining temperature .
VI.Improper cycle time .
VII.Improper length of rope .
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Causes:i.Operator negligence
ii.Dye bath hardness
iii.Improper Agitation of dyestuff
iv.Dye molecule deposition on the fabric
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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. - M:L ratio. - Improper washing after dyeing.
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Sources & Causes:1.Fluctuation of Temperature.2.Improper dosing time of dyes & chemicals.3.Batch to batch weight variation of dyes and chemicals.4.Dyes lot variation.5.Improper reel speed, pump speed, liquor ratio.6.Improper pretreatment.
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Sources & Causes:
I. Improper dyes solubility.
II. Hardness of water.
III. Faulty m/c speed, etc.
IV. Poor
V. migration property of dyes.
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Sources & Causes:
I. Poor opening of the fabric rope.
II. Shock cooling of synthetic material.
III. If pump pressure & reel speed is not equal.
IV. Faulty plaiting device.
V. For 100% cotton, if GSM>180, unbalanced structure,
presence of lycra, not properly heat set increase the
tendency to crease mark formation.
VI. Variation of heating & cooling rate.
VII. - More cycle time, more time fabric will be in folded
condition increase tendency
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Sources & Causes:
I. Improper mixing of the Softener.
II. Improper running time of the fabric during
application of softener.
III. Entanglement of the fabric during application of
softener.
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Sources & causes:
I.Soaping start before wash
II.CaCO3 or MgCO3 in soaping bath.
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Sources & Causes:
I.More oil & grease use the wheel, roller bearing into place.
II.To stay unclean the m/c.
III.Be decay the roller.
IV.Fabric waste.
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Sources & causes:
I.Hardness of the Dye house Water
II.Improper Mixing of Dyestuff
III.Temperature Up Down
IV.Sedimentation of Dyestuff
1. Long mark2. Loop mark 3. Brush problem4. Dhappa spot 5. Uneven even hairiness 6. Yellow spot 7. Water spot8. Iron spot 9. soda spot10.Out color 11.Lycra out12.Enzyme dust 13.Fly we 14.Patta fault
Ballooning shape. Radish shade. Squeezer mark. Dia mark. Dirty spot. Compaction /Press mark. Compacting hole. Crease mark. Calendaring crease. Oil Spot. Improper shrinkage. Bowing Crease Streak
HAIRINESS = Re Enzyme / light Enzyme Wash /normal wash on the dye bath
Oil SPOT= Use thinner and spot lifter for stripe or coloar
BOWING= Use Weft Stratiner divice (Mahalo/Bainco /paliva ) before Stanter .
SOFTNESS = Use good quality softner in every stage like Dyeing, stantoring , padder
SOIL SPOT= Re Wash in the Winch dyeing Machine
Dappa = Stripping of the fabric change padder pressure of Stanter
SIDE MARK (Calendar) = Re Calendar or cut the fault area
GSM HIGH = Send it to compactor run the machine With under feed the fabric
GSM LOW= Send it to compactor run the machine With overfeed the fabric
DYEING HOLE = Stripe carefully for light fabric and demeniralized the slub fabrics
COLOR SPOT = Stripping the fabric and re dyeing
CREA SEMARK = Calander or Compaction
UNEVEN SHADE = Stripping and re dyeing
RUNNING SHADE = Use yellow softner or Blue softner or redyeing if reject
DIA UP DOWN = Use compactor or Stanter