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Survey on dyeing faults

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Survey on dyeing faults

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  1. Southeast University KNIT DYEING WOVEN DYEING YARN DYEING

  2. Prepared By : Prepared By : Mazadul Hasan sheshir ID: 2010000400008 13th 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

  3. Faults in Dyeing Sector Faults in Dyeing Sector

  4. Yarn Dyeing Faults Yarn Dyein g Fault 1. Package un-level 2. Package to package shade variation 3. Color spot 4. Ring mark 5. Dirt mark

  5. 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

  6. Packag e Unlevel 2. Package to Package shade variation Causes: Causes: a. Improper setting of yarn packages in the machine a. Improper setting of yarn packages in the machine b. Lot mixing of the packages b. Lot mixing of the packages c. Count variation of packages c. Count variation of packages

  7. 3. Color Spot Packag e Unlevel P 2 P shade variatio n Causes: a. Floating of dye particles in the air b. Improper per-oxide killing c. Hardness of water d. Improper mixing of dyestuffs

  8. 5. Ring Mark Packag e Unlevel Causes: a. Improper drying of the packages b. Improper peroxide killing P 2 P shade variatio n Colo r Spot 4. Dirt Mark Causes: a. Dirty handling of the packages b. Presence of dust in the air Figure: Dirt mark

  9. Woven Woven Dyeing Fault Dyeing Fault Woven Dyeing Faults 1 1 2 2 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 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12

  10. 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 11 12 10 11 12 1. White Spot Causes: a. Foreign particles present on fabric before dyeing b. Foreign particles present in the solution c. Hairiness present in fabric from brushing

  11. 1 1 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 11 12 10 11 12 2. Color Spot Causes: 1. Dyes & chemicals factors: a. Poor 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

  12. 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 11 12 10 11 12 3. Crease Mark Causes: a.Lack of balance in construction of the fabric b.Pressure of padder roller c.Direct Heating or Shock cooling

  13. 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 11 12 10 11 12 4. Long Stripe Causes: a. Winding of yarn in padder roller b. Improper pressure during brushing

  14. 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 11 12 10 11 12 5. Uneven Shade Causes: a. Improper scouring b. Improper bleaching c. Improper mercerization d. Low solubility of dyes & chemicals e. Negligence of operators to solubilize dyes and chemicals

  15. 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 11 12 10 11 12 6. Running Shade Causes: a. Change in pick-up percentage along the length of the fabric b. Improper fabric Speed.

  16. 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 11 12 10 11 12 7. Listing Effect Causes: a. Improper padder pressure in different zones of padder roller (left, middle & right zone). b. Worn out squeeze roller.

  17. 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 11 12 10 11 12 8. Dirt Spot Causes: Presence of Dirt in the air Dirty handling of the fabric 9. Oil spot Cause: Oil dropped on the fabric

  18. 1 0 1 1 1 2 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10. Water Mark Cause: Water is dropped on the fabric after final drying. 11. Bug Spot Causes: 1. Insect present in any 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

  19. 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 center side shade v) Side to side shade. 3. Crease mark. 4. Dye spots. 5. Soda spots. 6. Hole

  20. 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. - M:L ratio. - Improper washing after dyeing.

  21. 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 are pretreated in different machines. ii) Fabric of different batches has different dye affinity. iii) Liquor ratio, cycle time, dye 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

  22. Causes: - More cycle time, more time fabric will be in folded condition increase tendency 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.

  23. 4. Dye Spot Causes: i.Operator negligence ii.Dye bath hardness iii.Improper Agitation of dyestuff iv.Dye molecule deposition on the fabric

  24. Causes: 1.Soaping start before wash 2.CaCO3 or MgCO3 in soaping bath.

  25. 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.

  26. Problem of dyeing a. Problem of shade matching Causes: 1. Dye factor 2. Process factor 3. Machine factor 4. Man factor b. Fastness problem Properties of Dyes & Chemicals affect fastness. c. Hand feel problem

  27. http://www.textilelab.blogspot.com (Visit ) My Facebook Textile related Pages 1. Yarn Manufacturing Technology Link : http://www.facebook.com/pages/Yarn-Manufacturing-Technology/485014954866808 2. Fabric Manufacturing Technology Link : http://www.facebook.com/pages/Fabric-Manufacturing-Technology/459520217425605 3. Garments Manufacturing Technology Link : 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

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