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Knit dyeing faults and remedies

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Knit dyeing faults and remedies

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  1. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile KNIT DYEING FAULTS AND REMEDIES KNIT DYEING FAULTS AND REMEDIES KNIT DYEING FAULTS AND REMEDIES 1 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  2. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile 2 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  3. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Letter of Transmittal Letter of Transmittal Letter of Transmittal To Rajib Shaha Assistant Professor Department of Textile Engineering Southeast University Southeast University Southeast University To Rajib Shaha Assistant Professor Department of Textile Engineering Department of Textile Engineering To Rajib Shaha Assistant Professor Subject: submission of Project Report on “Knit dyeing faults & remedies”. Subject: submission of Project Report on “Knit dyeing faults & remedies”. Subject: submission of Project Report on “Knit dyeing faults & remedies”. Sir, Sir, 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. in Textile Engineering requirement that bears three (03) credit hours under your supervision. in Textile Engineering requirement that bears three (03) credit hours under your supervision. 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. we are submitting our Project Report on “Knit dyeing faults & remedies” as a part of our B.Sc. 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 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. kind assessment. kind assessment. 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 recommendations and valued suggestions & will cordially receive this Project Report for your We therefore request and expect that, you will appreciate us with any sort of Sincerely Yours, Sincerely Yours, Sincerely Yours, Ariful Islam ID: 2010000400005 Mazadul Hasan ID: 2010000400008 Mazadul Hasan ID: 2010000400008 Mazadul Hasan ID: 2010000400008 Ariful Islam ID: 2010000400005 Ariful Islam ID: 2010000400005 Major : Wet Processing Technology Batch: 13th Department of Textile Engineering Southeast University Southeast University Southeast University Major : Wet Processing Technology Batch: 13th Department of Textile Engineering Department of Textile Engineering Major : Wet Processing Technology Batch: 13th 3 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  4. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Supervising Faculty’s Approval Supervising Faculty’s Approval Supervising Faculty’s Approval SOUTHEAST UNIVERSITY SOUTHEAST UNIVERSITY SOUTHEAST UNIVERSITY Department of Textile Engineering Department of Textile Engineering Department of Textile Engineering ……………………………………………………………… ……………………………………………………………… ……………………………………………………………… Rajib Shaha Rajib Shaha Rajib Shaha Assistant Professor Department of Textile Engineering Southeast University I/A 251, 252 Tejgaon, Dhaka Cell No.: 01726419580 Cell No.: 01726419580 Cell No.: 01726419580 Assistant Professor Department of Textile Engineering Southeast University I/A 251, 252 Tejgaon, Dhaka I/A 251, 252 Tejgaon, Dhaka Assistant Professor Department of Textile Engineering Southeast University 4 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  5. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile ACKNOWLEDGEMENT ACKNOWLEDGEMENT 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 training and this report. May your name be exalted, honored and glorified. industrial training and this report. May your name be exalted, honored and glorified. At first my gratefulness goes to Almighty Allah to give me strength and ability to complete the At first my gratefulness goes to Almighty Allah to give me strength and ability to complete the 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. Hassan.for providing us the chance to complete our Industrial Attachment with Knit Concern Ltd. Hassan.for providing us the chance to complete our Industrial Attachment with Knit Concern Ltd. 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 highly delighted to express our regards & gratitude to honorable Principal Prof. Syed Fakhrul Industrial Attachment Course is an academic function of the College of Textile Technology. We are Special thanks to our supervising teacher, tremendous support and guidance throughout my training period, without whose help it would not have been possible to complete the training successfully. not have been possible to complete the training successfully. not have been possible to complete the training successfully. Special thanks to our supervising teacher, tremendous support and guidance throughout my training period, without whose help it would tremendous support and guidance throughout my training period, without whose help it would Special thanks to our supervising teacher, Rajib Shaha to whom I am extremely indebted for his Rajib Shaha to whom I am extremely indebted for his Rajib Shaha to whom I am extremely indebted for his 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. operation, support and valuable advices. operation, support and valuable advices. 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- successfully. our gratitude also goes to all the employees of Knit Concern Ltd. for their sincere co- 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 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. all our efforts. all our efforts. 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 of Wet Processing Department for their kind inspiration & help, which remain as the backdrop of Above all, we would like to acknowledge our deep debt to all teachers of our college & particularly Finally, we would like to acknowledge that we remain responsible for the inadequacies & errors, which doubtless remain in the following report. which doubtless remain in the following report. which doubtless remain in the following report. Finally, we would like to acknowledge that we remain responsible for the inadequacies & errors, Finally, we would like to acknowledge that we remain responsible for the inadequacies & errors, 5 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  6. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Abstract Abstract 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 . Dyeing faults any Find out the Remedies of all faults . Dyeing faults any Find out the Remedies of all faults . 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 Knit Concern group . We collect all physical sample of fault. We have studied the effect of Knit 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 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] each and every step of fabric processing. [1] each and every step of fabric processing. [1] 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 RIGHT" dyeing quality can be easily achieved by strictly adhering to process control parameters of 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 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. these dyeing problems helps the processes as a ready recockener for avoiding these problems. these dyeing problems helps the processes as a ready recockener for avoiding these problems. 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 machine and other factors of processing for damage about the possible causes and remedies of In this paper an attempt has been made to highlight the various problems encountered due to men, 6 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  7. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Project Description: Project Description: Project Description: The study was intended on the topic, ‘Knit dyeing Faults and Remedies’ which carry out a great The study was intended on the topic, ‘Knit dyeing Faults and Remedies’ which carry out a great 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- importance on the textile sector. Textile and confection sector is one of the leading fields of socio- 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. economical activity, regarding its technological state, economical efficiency and social interaction. 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 Marketing conditions became harder within the recent years of 2000, urging this crucial sector for 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. the economy to aim taking new and radical measures and bounding it to determine the quality. the economy to aim taking new and radical measures and bounding it to determine the quality. 7 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  8. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Origin of the report Origin of the report Origin of the report Name of the factory: KNIT CONCERN LIMITED Name of the factory: KNIT CONCERN LIMITED Name of the factory: KNIT CONCERN LIMITED Type : 100 % Export Oriented Composite knitwear Industry Type : 100 % Export Oriented Composite knitwear Industry Type : 100 % Export Oriented Composite knitwear Industry Year of Establishment : 1998 Year of Establishment : 1998 Year of Establishment : 1998 Status ( Legal Structure ) : Private Limited Company Status ( Legal Structure ) : Private Limited Company Status ( Legal Structure ) : Private Limited Company Annual Production capacity : 10000 ton of knit fabric ( Open & tubular form ) Annual Production capacity : 10000 ton of knit fabric ( Open & tubular form ) Annual Production capacity : 10000 ton of knit fabric ( Open & tubular form ) Total Manpower: Around 8000 Total Manpower: Around 8000 Total Manpower: Around 8000 Address : 62 ,Water Works Road, Godnail.Narayanganj, Bangladesh. Address : 62 ,Water Works Road, Godnail.Narayanganj, Bangladesh. Address : 62 ,Water Works Road, Godnail.Narayanganj, Bangladesh. Telephone Number Fax Number URL 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 Production capacity: approximately 50 ton/day Production capacity: approximately 50 ton/day Telephone Number Fax Number URL 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. thousands square ft area. Telephone Number Fax Number URL 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 : : : : : : : : : +88 – 02 - 7641086 + 88 – 02 – 7641087 http://www.knitconcern.com http://www.knitconcern.com http://www.knitconcern.com +88 – 02 - 7641086 + 88 – 02 – 7641087 + 88 – 02 – 7641087 +88 – 02 - 7641086 8 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  9. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile CONTENTS CONTENTS CONTENTS Page No. Page No. Page No. Acknowledgement………………………………………………………………........................................3 Abstract……………………………………………………………………………………………………………………..4 Project Description…………………………………………………………………………………………………….5 Origin of the report……………………………………………………………………………………………………6 1. INTRODUCTION…………………………………………………………………………………………………..8 2. PROJECT OBJECTIVE ……………………………………………………………………………………………9 2. PROJECT OBJECTIVE ……………………………………………………………………………………………9 2. PROJECT OBJECTIVE ……………………………………………………………………………………………9 Acknowledgement………………………………………………………………........................................3 Abstract……………………………………………………………………………………………………………………..4 Project Description…………………………………………………………………………………………………….5 Origin of the report……………………………………………………………………………………………………6 1. INTRODUCTION…………………………………………………………………………………………………..8 1. INTRODUCTION…………………………………………………………………………………………………..8 Acknowledgement………………………………………………………………........................................3 Abstract……………………………………………………………………………………………………………………..4 Project Description…………………………………………………………………………………………………….5 Origin of the report……………………………………………………………………………………………………6 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 3.7.4 Types of Dyeing Faults ……………………………………………………………………….. 18-19 3.7.4 Types of Dyeing Faults ……………………………………………………………………….. 18-19 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 Dyeing Faults…………………………………………………………………………………………17 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 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 4.7Parameters of dyeing & Finishing M/C: …………………………………………………………………25-29 4.7Parameters of dyeing & Finishing M/C: …………………………………………………………………25-29 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 4.5 Production parameters: …………………………………………………………………………………………25 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 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 5.4 Dyeing Faults………………………………………………………………………………………………………….50-63 5.4 Dyeing Faults………………………………………………………………………………………………………….50-63 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 5.3 Finishing Faults ……………………………………………………………………………………………………..43-49 5. ANALYSIS DATA 5.1 Grey Fabric faults ………………………………………………………………………………………………..31-34 5.2 Pre Treatment faults ……………………………………………………………………………………………35-39 5.3 Optical brightener fault…………………………………………………………………………………………40-42 6.RESULT & DISCUSSION ………………………………………………………………………………………………66-74 CONCLUTION REFIRANCE THANKS THANKS THANKS 6.RESULT & DISCUSSION ………………………………………………………………………………………………66-74 CONCLUTION REFIRANCE REFIRANCE 6.RESULT & DISCUSSION ………………………………………………………………………………………………66-74 CONCLUTION 9 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  10. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Introduction: Introduction: 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. regulations, and competitiveness. regulations, and competitiveness. 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 related requirements, cost reduction, security, energy & water saving, toxicology, hygiene legal 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 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. prices, but in fact would mean "Doing it right the first time" thereby reduce the costs. prices, but in fact would mean "Doing it right the first time" thereby reduce the costs. 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 competitive edge is to lay emphasis on 'Quality'. Good quality does not necessarily mean increased 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 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. be astrology or palmistry, but it needs the fullest knowledge of basic facts. be astrology or palmistry, but it needs the fullest knowledge of basic facts. 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 manufacturing unit has a number of problems, however problem solving cannot be considered to 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 10 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  11. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Project Object: Project Object: Project Object: 1. 1. 1. Research. Research. Research. 2. 2. 2. Analysis various Fault in different process of wet processing and find out the remedial measure. Remedies of these faults. Remedies of these faults. Remedies of these faults. Analysis various Fault in different process of wet processing and find out the remedial measure. measure. Analysis various Fault in different process of wet processing and find out the remedial 3. 3. 3. 4. 4. 4. Selection of raw materials. Selection of raw materials. Selection of raw materials. 5. 5. 5. Product testing. Product testing. Product testing. 6. 6. 6. Product Quality improvement. Product Quality improvement. Product Quality improvement. 7. 7. 7. Reduce wastage. Reduce wastage. Reduce wastage. 8. 8. 8. To improve the appearance of the fabric, that is, make it more attractive or lustrous by operations like calendaring, optical whitening, etc. To improve the feel of the fabric by softening, stiffening, etc. To improve the feel of the fabric by softening, stiffening, etc. To improve the feel of the fabric by softening, stiffening, etc. To improve the appearance of the fabric, that is, make it more attractive or lustrous by operations like calendaring, optical whitening, etc. operations like calendaring, optical whitening, etc. To improve the appearance of the fabric, that is, make it more attractive or lustrous by 9. 9. 9. 10. To cover faults in the original fabric. 10. To cover faults in the original fabric. 10. To cover faults in the original fabric. 11. To improve wearing qualities of cloth by making it shrink resistant, crease resistant or free from pills and soiling. 12. To make garments hold their shape and enable them to be worn without ironing. 12. To make garments hold their shape and enable them to be worn without ironing. 12. To make garments hold their shape and enable them to be worn without ironing. 11. To improve wearing qualities of cloth by making it shrink resistant, crease resistant or free from pills and soiling. from pills and soiling. 11. To improve wearing qualities of cloth by making it shrink resistant, crease resistant or free 13. To set the texture of certain fabrics and make others dimensionally stable. 13. To set the texture of certain fabrics and make others dimensionally stable. 13. To set the texture of certain fabrics and make others dimensionally stable. 14. To produce stronger and more durable fabrics. 14. To produce stronger and more durable fabrics. 14. To produce stronger and more durable fabrics. 15. To maximize the production. 15. To maximize the production. 15. To maximize the production. 16. To minimize the production cost. 16. To minimize the production cost. 16. To minimize the production cost. 17. To find out the wasting time during a product making and to minimize the wasting time. 17. To find out the wasting time during a product making and to minimize the wasting time. 17. To find out the wasting time during a product making and to minimize the wasting time. 18. Find out the problem restricting the production, generating proper solutions and implement them in a proper way. them in a proper way. them in a proper way. 18. Find out the problem restricting the production, generating proper solutions and implement 18. Find out the problem restricting the production, generating proper solutions and implement 11 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  12. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile CHAPTER - 3 CHAPTER - 3 CHAPTER - 3 LITURATURE REVIEW LITURATURE REVIEW LITURATURE REVIEW 12 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  13. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile 3.1. Dyeing Flow Chart: Gray Fabric Inspection Senging Diminalilazation Scouring Bleaching Enzyme Wash Dyeing Fastness Improvement Softening Finishing Tube Finish Tube Finish Open Finish Special Finish Sqizer / Padder Sqizer / Padder Slitting Stantoring Dryer Dryer 1) Sueding 2) Brushing 3) Creeping Calendaring Calendaring Open Compacting Open Compacting Inspection Tube compacting Tube compacting Delivery Inspection Inspection Delivery Delivery Note: Red Marked area have chance to make fabric Fault Note: Red Marked area have chance to make fabric Fault Note: Red Marked area have chance to make fabric Fault 13 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  14. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile 3.2 SCOURING PROCESS: 3.2 SCOURING PROCESS: 3.2 SCOURING PROCESS: The tern scouring applies to the removal of impurities such as oil, wax gum, soluble impurities and solid dirt commonly found in textile material. The process consists essentially of treatment with alkali, a good supply of water is essential. alkali, a good supply of water is essential. alkali, a good supply of water is essential. The tern scouring applies to the removal of impurities such as oil, wax gum, soluble impurities and solid dirt commonly found in textile material. The process consists essentially of treatment with solid dirt commonly found in textile material. The process consists essentially of treatment with The tern scouring applies to the removal of impurities such as oil, wax gum, soluble impurities and Bleaching. Bleaching is destruction of natural coloring matter to produce white fabrics and must be accomplished with a minimum damage to the cotton being bleached. Bleaching is not a cleaning process in the sense of scouring. This process does not remove dirt. process in the sense of scouring. This process does not remove dirt. process in the sense of scouring. This process does not remove dirt. Bleaching. Bleaching is destruction of natural coloring matter to produce white fabrics and must be accomplished with a minimum damage to the cotton being bleached. Bleaching is not a cleaning accomplished with a minimum damage to the cotton being bleached. Bleaching is not a cleaning Bleaching. Bleaching is destruction of natural coloring matter to produce white fabrics and must be Recipe for scouring/ Bleaching : -[9] Sequestering Agent (Celion BDW) :0.6 gm/L Wetting Agent ( KappaWet BOSS): 0.7 gm/L Antifoam (AF 2000) : 0.2 gm/L Ant crease (Kappavon FCB): 0.8 gm/l Stabilizer ( Equasec STA ) : 0.1 gm/L Caustic soda (NaOH): 1 gm/L (scouring Chemical) H2O20.6 gm/L (Bleaching Chemical ) M: L: 1:6 or 1:8 Temperature(▫C): 98 c Time: 60' PH= 11.5-12 PH= 11.5-12 PH= 11.5-12 Recipe for scouring/ Bleaching : -[9] Sequestering Agent (Celion BDW) :0.6 gm/L Wetting Agent ( KappaWet BOSS): 0.7 gm/L Antifoam (AF 2000) : 0.2 gm/L Ant crease (Kappavon FCB): 0.8 gm/l Stabilizer ( Equasec STA ) : 0.1 gm/L Caustic soda (NaOH): 1 gm/L (scouring Chemical) H2O20.6 gm/L (Bleaching Chemical ) M: L: 1:6 or 1:8 Temperature(▫C): 98 c Time: 60' Time: 60' Recipe for scouring/ Bleaching : -[9] Sequestering Agent (Celion BDW) :0.6 gm/L Wetting Agent ( KappaWet BOSS): 0.7 gm/L Antifoam (AF 2000) : 0.2 gm/L Ant crease (Kappavon FCB): 0.8 gm/l Stabilizer ( Equasec STA ) : 0.1 gm/L Caustic soda (NaOH): 1 gm/L (scouring Chemical) H2O20.6 gm/L (Bleaching Chemical ) M: L: 1:6 or 1:8 Temperature(▫C): 98 c 3.3 Special Process: Deminelilazation Hot 3.3 Special Process: Deminelilazation Hot 3.3 Special Process: Deminelilazation Hot For Lycra Fabrics : To Remove The lubrication so that it don’t effect on White or light s hade and don’t create Yellowness on the Fabrics don’t create Yellowness on the Fabrics don’t create Yellowness on the Fabrics For Lycra Fabrics : To Remove The lubrication so that it don’t effect on White or light s hade and For Lycra Fabrics : To Remove The lubrication so that it don’t effect on White or light s hade and Recipe : Recipe : Recipe : Ant crease (Kappavon FCB): 0.2 gm/l Basic Chemical (Kappa R 98) : 0.5 gm/l Wetting Agent ( KappaWet BOSS): 0.2 gm/L Parameter: 800c /20 min Parameter: 800c /20 min Parameter: 800c /20 min Ant crease (Kappavon FCB): 0.2 gm/l Basic Chemical (Kappa R 98) : 0.5 gm/l Wetting Agent ( KappaWet BOSS): 0.2 gm/L Wetting Agent ( KappaWet BOSS): 0.2 gm/L Ant crease (Kappavon FCB): 0.2 gm/l Basic Chemical (Kappa R 98) : 0.5 gm/l For Slub Fabrics : To Remove the Ferrous (Ca,Mg ,Fe) Salt fron the Thin portion of the Slub yarn So that it don’t broke during the SCOURING PROCESS react With NaOH and make Hole On the Fabrics that it don’t broke during the SCOURING PROCESS react With NaOH and make Hole On the Fabrics that it don’t broke during the SCOURING PROCESS react With NaOH and make Hole On the Fabrics For Slub Fabrics : To Remove the Ferrous (Ca,Mg ,Fe) Salt fron the Thin portion of the Slub yarn So For Slub Fabrics : To Remove the Ferrous (Ca,Mg ,Fe) Salt fron the Thin portion of the Slub yarn So Ant crease (Kappavon FCB): 0.3 gm/l Acid (Oxalic Acid –Core neutralizer ) : 0.5 gm/l Sequestering Agent (Celion BDW) : 0.3 gm/L Parameter: 600c /20 min Parameter: 600c /20 min Parameter: 600c /20 min Ant crease (Kappavon FCB): 0.3 gm/l Acid (Oxalic Acid –Core neutralizer ) : 0.5 gm/l Sequestering Agent (Celion BDW) : 0.3 gm/L Sequestering Agent (Celion BDW) : 0.3 gm/L Ant crease (Kappavon FCB): 0.3 gm/l Acid (Oxalic Acid –Core neutralizer ) : 0.5 gm/l 14 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  15. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile 3.4 Dyeing : 3.4 Dyeing : 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. performed on fibre, thread or on some clothing. performed on fibre, thread or on some clothing. 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 process are performed more often on Woven fabric or knit, however those can be also The dyeing aim is to colour the textile material in a uniform way. These two stages of the Types of dyeing e work for Types of dyeing e work for Types of dyeing e work for 1. Knit Dyeing 2. Yarn Dyeing 2. Yarn Dyeing 2. Yarn Dyeing 1. Knit Dyeing 1. Knit Dyeing 3.5 Finishing: 3.5 Finishing: 3.5 Finishing: Textile finishing, in a restricted sense, is the term used for a series of processes to which all bleached, dyed, printed & certain greige fabrics are subjected before they are put to market. It’s one of the most important operation in knit processing. It’s one of the most important operation in knit processing. It’s one of the most important operation in knit processing. Textile finishing, in a restricted sense, is the term used for a series of processes to which all bleached, dyed, printed & certain greige fabrics are subjected before they are put to market. bleached, dyed, printed & certain greige fabrics are subjected before they are put to market. Textile finishing, in a restricted sense, is the term used for a series of processes to which all DEFINITION OF DEFECT: DEFINITION OF DEFECT: DEFINITION OF DEFECT: The length of the defect is used to determine the penalty points. Only major defects are considered. A major defect is any defect, if found on a finished product, would classify the product as a B- grade. Any defect of a continuous nature shall be assigned four points for each meter in which it occurs. Severe defects are assigned the maximum four points for each meter in which they occur. they occur. they occur. The length of the defect is used to determine the penalty points. Only major defects are considered. A major defect is any defect, if found on a finished product, would classify the product as a B- grade. Any defect of a continuous nature shall be assigned four points for each meter in which it occurs. Severe defects are assigned the maximum four points for each meter in which which it occurs. Severe defects are assigned the maximum four points for each meter in which The length of the defect is used to determine the penalty points. Only major defects are considered. A major defect is any defect, if found on a finished product, would classify the product as a B- grade. Any defect of a continuous nature shall be assigned four points for each meter in Example: Regardless of size, a hole would be penalized four points. Example: Regardless of size, a hole would be penalized four points. Example: Regardless of size, a hole would be penalized four points. Continuing conditions such as barre, side center side shading, roll to roll shading, narrow or irregular width, creasing, uneven finish shall be counted four points for every meter within the shipment that is found to contain these conditions, provided that the article that is to be made from this fabric is classified B-grade due to this fault. The maximum penalty for any one-meter shall not be more than four points. A minor defect is any defect that does not classify the product as B-grade because of either severity or location. When inspecting fabric before cutting, it is necessary to rate questionable defects as major, since the inspector will not know where the defect may occur on the item. defect may occur on the item. defect may occur on the item. Continuing conditions such as barre, side center side shading, roll to roll shading, narrow or irregular width, creasing, uneven finish shall be counted four points for every meter within the shipment that is found to contain these conditions, provided that the article that is to be made from this fabric is classified B-grade due to this fault. The maximum penalty for any one-meter shall not be more than four points. A minor defect is any defect that does not classify the product as B-grade because of either severity or location. When inspecting fabric before cutting, it is necessary to rate questionable defects as major, since the inspector will not know where the necessary to rate questionable defects as major, since the inspector will not know where the Continuing conditions such as barre, side center side shading, roll to roll shading, narrow or irregular width, creasing, uneven finish shall be counted four points for every meter within the shipment that is found to contain these conditions, provided that the article that is to be made from this fabric is classified B-grade due to this fault. The maximum penalty for any one-meter shall not be more than four points. A minor defect is any defect that does not classify the product as B-grade because of either severity or location. When inspecting fabric before cutting, it is RUNNING DEFECTS: RUNNING DEFECTS: RUNNING DEFECTS: Any major defect found to repeat and / or run in a continuous manner will constitute a running defect. All major running defects must be assigned four penalty points to every meter in the roll where it occurs. where it occurs. where it occurs. Any major defect found to repeat and / or run in a continuous manner will constitute a running defect. All major running defects must be assigned four penalty points to every meter in the roll defect. All major running defects must be assigned four penalty points to every meter in the roll Any major defect found to repeat and / or run in a continuous manner will constitute a running 15 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  16. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile FULL WIDTH DEFECTS: A full width major defect would cause that meter of fabric to be assigned four penalty points. A full width major defect would cause that meter of fabric to be assigned four penalty points. A full width major defect would cause that meter of fabric to be assigned four penalty points. FULL WIDTH DEFECTS: FULL WIDTH DEFECTS: FABRIC WIDTH: Fabric width will be checked minimum of three times during the inspection of a roll (beginning, middle and end of the roll).Rolls having width less than the specified are potential problems. In such cases width deviation of more than 1% would constitute a major fault. Overall, fabric width is measured from out side of the selvage to the outside of the opposite selvage. measured from out side of the selvage to the outside of the opposite selvage. measured from out side of the selvage to the outside of the opposite selvage. FABRIC WIDTH: Fabric width will be checked minimum of three times during the inspection of a roll (beginning, middle and end of the roll).Rolls having width less than the specified are potential problems. In such cases width deviation of more than 1% would constitute a major fault. Overall, fabric width is such cases width deviation of more than 1% would constitute a major fault. Overall, fabric width is FABRIC WIDTH: Fabric width will be checked minimum of three times during the inspection of a roll (beginning, middle and end of the roll).Rolls having width less than the specified are potential problems. In ROLL LENGTH: Rolls having meters less than that stated on the packing are a problem. Any roll having more than 1% lesser fabric than that specified is rejected. The entire shipment shall be rejected if the total measured meters in the sample audit are more than 1% short that what is declared on the packing. packing. packing. ROLL LENGTH: Rolls having meters less than that stated on the packing are a problem. Any roll having more than 1% lesser fabric than that specified is rejected. The entire shipment shall be rejected if the total measured meters in the sample audit are more than 1% short that what is declared on the measured meters in the sample audit are more than 1% short that what is declared on the ROLL LENGTH: Rolls having meters less than that stated on the packing are a problem. Any roll having more than 1% lesser fabric than that specified is rejected. The entire shipment shall be rejected if the total SPLICES: Rolls can be composed of several spliced parts. No roll shall be accepted that contains a splice less than twenty five ( 25 ) meters in length unless otherwise expressly accepted. Ensure that the 95% of the shipment contains 100 meter plus fabric length if the fabric is being used for made - ups. In case of piece goods, the fabric length and the number of splices / roll are strictly followed as per the requirement of the customer. the requirement of the customer. the requirement of the customer. SPLICES: Rolls can be composed of several spliced parts. No roll shall be accepted that contains a splice less than twenty five ( 25 ) meters in length unless otherwise expressly accepted. Ensure that the 95% of the shipment contains 100 meter plus fabric length if the fabric is being used for made - ups. In case of piece goods, the fabric length and the number of splices / roll are strictly followed as per case of piece goods, the fabric length and the number of splices / roll are strictly followed as per SPLICES: Rolls can be composed of several spliced parts. No roll shall be accepted that contains a splice less than twenty five ( 25 ) meters in length unless otherwise expressly accepted. Ensure that the 95% of the shipment contains 100 meter plus fabric length if the fabric is being used for made - ups. In BOW & SKEW: No roll shall be accepted as first quality that exhibit bow or skew more than: No roll shall be accepted as first quality that exhibit bow or skew more than: No roll shall be accepted as first quality that exhibit bow or skew more than: BOW & SKEW: BOW & SKEW: Fabric Width Up to 45 inches 60 inches 90 inches and above Maximum Bow or Skew Design Maximum Bow or Skew Design 2.0% 2.0% 2.0% Print/dyes Deviation Print/dyes Deviation 2.0% 2.0% 2.0% The above is subject to change if buyer requires a tighter tolerance / nature of design / end use of the fabric. Tolerance for bowed condition not affecting the full width will be fractionalized part of the maximums as stated above according to the area affected by the bow. Penalty points will not be assigned for fabrics found to have conditions of bowing in excess of the above stated tolerances but shall be noted in the inspection report. And if any fabric exhibits bow or skew where its end use becomes doubtful, then that fabric will be rejected. where its end use becomes doubtful, then that fabric will be rejected. where its end use becomes doubtful, then that fabric will be rejected. The above is subject to change if buyer requires a tighter tolerance / nature of design / end use of the fabric. Tolerance for bowed condition not affecting the full width will be fractionalized part of the maximums as stated above according to the area affected by the bow. Penalty points will not be assigned for fabrics found to have conditions of bowing in excess of the above stated tolerances but shall be noted in the inspection report. And if any fabric exhibits bow or skew tolerances but shall be noted in the inspection report. And if any fabric exhibits bow or skew The above is subject to change if buyer requires a tighter tolerance / nature of design / end use of the fabric. Tolerance for bowed condition not affecting the full width will be fractionalized part of the maximums as stated above according to the area affected by the bow. Penalty points will not be assigned for fabrics found to have conditions of bowing in excess of the above stated FABRIC ODORS: No roll shall be accepted that exhibits objectionable odors. FABRIC ODORS: No roll shall be accepted that exhibits objectionable odors. FABRIC ODORS: No roll shall be accepted that exhibits objectionable odors. 16 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  17. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile HOLES: All defects that break the fabric, regardless of size, shall be penalized a maximum of four points. A hole consists of two or more broken yarns. points. A hole consists of two or more broken yarns. points. A hole consists of two or more broken yarns. HOLES: All defects that break the fabric, regardless of size, shall be penalized a maximum of four HOLES: All defects that break the fabric, regardless of size, shall be penalized a maximum of four DYEING FAULTS: DYEING FAULTS: 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 . the remedies of these dyeing faults . the remedies of these 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 quality of the fabrics . So to overcome from this faults we have to know the causes and The faults which are visible after dyeing are called Dyeing faults . These faults descries the TYPES OF FAULTS Dyeing faults can be described on the following basic things 1. Unlevelness ( due to dyeing conditions ) 1. Unlevelness ( due to dyeing conditions ) 1. Unlevelness ( due to dyeing conditions ) TYPES OF FAULTS Dyeing faults can be described on the following basic things Dyeing faults can be described on the following basic things TYPES OF FAULTS i. ii. iii. iii. iii. i. ii. ii. i. Ending problems Cloudy dyeing Pale areas Pale areas Pale areas Ending problems Cloudy dyeing Cloudy dyeing Ending problems 2. Unlevelness ( due to material ) i. 3. Unlevelness ( due to other reasons ) i. ii. iii. 4. Reproducibility i. ii. iii. iv. 5. Fastness properties i. ii. ii. ii. 2. Unlevelness ( due to material ) i. 3. Unlevelness ( due to other reasons ) i. ii. iii. 4. Reproducibility i. ii. iii. iv. 5. Fastness properties i. i. 2. Unlevelness ( due to material ) i. 3. Unlevelness ( due to other reasons ) i. ii. iii. 4. Reproducibility i. ii. iii. iv. 5. Fastness properties Barriness Barriness Barriness Skitterness Listing Pale areas after dyeing Pale areas after dyeing Pale areas after dyeing Skitterness Listing Listing Skitterness Deviation of shade Dyeing too pale Precipitates in the dyebath Change of shade Change of shade Change of shade Deviation of shade Dyeing too pale Precipitates in the dyebath Precipitates in the dyebath Deviation of shade Dyeing too pale Unexpectedly poor light fastness Unexpectedly poor wet and rub fastness Unexpectedly poor wet and rub fastness Unexpectedly poor wet and rub fastness Unexpectedly poor light fastness Unexpectedly poor light fastness 6. Spots, marks 6. Spots, marks 6. Spots, marks Precipitates in the dyebath Singeing droplets Change of shade (e.g. blue spots in brilliant red shades) Dark spots Specks Dirt spots 7. Appearance of the goods 7. Appearance of the goods 7. Appearance of the goods i. ii. iii. iv. v. vi. vi. vi. i. ii. iii. iv. v. v. i. ii. iii. iv. Precipitates in the dyebath Singeing droplets Change of shade (e.g. blue spots in brilliant red shades) Dark spots Specks Dirt spots Dirt spots Precipitates in the dyebath Singeing droplets Change of shade (e.g. blue spots in brilliant red shades) Dark spots Specks 17 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  18. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile i. ii. iii. iv. v. vi. vii. viii. viii. viii. i. ii. iii. iv. v. vi. vii. vii. i. ii. iii. iv. v. vi. Dimensional stability (shrinkage) Creasing Chafe marks Stitch distortion (knits) Moire effects (on beam) Lustre Handle Pilling (staple fibres) Pilling (staple fibres) Pilling (staple fibres) Dimensional stability (shrinkage) Creasing Chafe marks Stitch distortion (knits) Moire effects (on beam) Lustre Handle Handle Dimensional stability (shrinkage) Creasing Chafe marks Stitch distortion (knits) Moire effects (on beam) Lustre 8. Other problems 8. Other problems 8. Other problems i. ii. iii. iv. iv. iv. i. ii. iii. iii. i. ii. Difficulty with heavy shades on fine denier yarn Soiling of machine Frosting on goods Poor running of material in subsequent processing Poor running of material in subsequent processing Poor running of material in subsequent processing Difficulty with heavy shades on fine denier yarn Soiling of machine Frosting on goods Frosting on goods Difficulty with heavy shades on fine denier yarn Soiling of machine Some definition Wet processing fault: Crease mark: Uneven heat control during process. Crease mark: Uneven heat control during process. Some definition Wet processing fault: Some definition Wet processing fault: Unevenness: If dyestuffs are not fixed with fabric uniformly causes this problem. Unevenness: If dyestuffs are not fixed with fabric uniformly causes this problem. Unevenness: If dyestuffs are not fixed with fabric uniformly causes this problem. Patches: This problem causes due to different color on some portion of fabric. Patches: This problem causes due to different color on some portion of fabric. Patches: This problem causes due to different color on some portion of fabric. Crumple mark: This problem is as like crease mark but looks meeting effect over PC fabric. Crumple mark: This problem is as like crease mark but looks meeting effect over PC fabric. Crumple mark: This problem is as like crease mark but looks meeting effect over PC fabric. Dye stain: Marks of color on fabric surface cause this problem. Dye stain: Marks of color on fabric surface cause this problem. Dirty mark: This mark can appear anywhere in fabric. Dirty mark: This mark can appear anywhere in fabric. Rub mark: Caused by friction with metallic component of m/c: Rub mark: Caused by friction with metallic component of m/c: Water sports: One to accumulation of water. Water sports: One to accumulation of water. Back Fabric Seam Impression : Backing fabric is often used to cushion fabric being printed. Back Fabric Seam Impression : Backing fabric is often used to cushion fabric being printed. Back Fabric Seam Impression : Backing fabric is often used to cushion fabric being printed. If there is a joining seam in the backing fabric, an impression will result on printed fabric. If there is a joining seam in the backing fabric, an impression will result on printed fabric. If there is a joining seam in the backing fabric, an impression will result on printed fabric. Broken Color Pattern: Usually caused by colored yarn out of place on frame. Broken Color Pattern: Usually caused by colored yarn out of place on frame. Broken Color Pattern: Usually caused by colored yarn out of place on frame. Color Out: Color out is the result of color running low in reservoir on printing machine Color Out: Color out is the result of color running low in reservoir on printing machine Color Out: Color out is the result of color running low in reservoir on printing machine Color Smears: Color Smears are the result of color being smeared during printing. Color Smears: Color Smears are the result of color being smeared during printing. Color Smears: Color Smears are the result of color being smeared during printing. 18 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  19. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Crease Mark : Differs from crease streak in that streak will probably appear for an entire Crease Mark : Differs from crease streak in that streak will probably appear for an entire Crease Mark : Differs from crease streak in that streak will probably appear for an entire roll. Crease mark appears when creases are caused by fabric folds in the finishing process. roll. Crease mark appears when creases are caused by fabric folds in the finishing process. roll. Crease mark appears when creases are caused by fabric folds in the finishing process. Often discoloration is a problem. Often discoloration is a problem. Often discoloration is a problem. Drop Stitching : Drop stitching is resulted from malfunctioning needle or jack appearing as Drop Stitching : Drop stitching is resulted from malfunctioning needle or jack appearing as Drop Stitching : Drop stitching is resulted from malfunctioning needle or jack appearing as holes or missing stitches. holes or missing stitches. holes or missing stitches. Dye Streak in Printing : Drop stitching is resulted from malfunctioning needle or jack Dye Streak in Printing : Drop stitching is resulted from malfunctioning needle or jack Dye Streak in Printing : Drop stitching is resulted from malfunctioning needle or jack appearing as holes or missing stitches. appearing as holes or missing stitches. appearing as holes or missing stitches. Dye Streak in Printing : Results from a damaged doctor blade or a blade not cleaned Dye Streak in Printing : Results from a damaged doctor blade or a blade not cleaned Dye Streak in Printing : Results from a damaged doctor blade or a blade not cleaned properly. Usually a long streak until the operator notices the problem. properly. Usually a long streak until the operator notices the problem. properly. Usually a long streak until the operator notices the problem. Mottled : Mottles occurs when colors applied unevenly during printing. Mottled : Mottles occurs when colors applied unevenly during printing. Mottled : Mottles occurs when colors applied unevenly during printing. Needle Line : Needle Line is caused by bent needle forming distorted stitches in a vertical Needle Line : Needle Line is caused by bent needle forming distorted stitches in a vertical Needle Line : Needle Line is caused by bent needle forming distorted stitches in a vertical line. line. line. Pin Holes : Pin Holes : Pin Holes : Pin holes along selvage caused by pins holding fabric while it processes Pin holes along selvage caused by pins holding fabric while it processes Pin holes along selvage caused by pins holding fabric while it processes through tender frame. through tender frame. through tender frame. Printing Machine Stop Mark : Printing Machine Stop Mark : Printing Machine Stop Mark : Dye or ink smudged along width of fabric as a result of the Dye or ink smudged along width of fabric as a result of the Dye or ink smudged along width of fabric as a result of the printing machine stopping. printing machine stopping. printing machine stopping. Print Out of Repair : Print Out of Repair : Print Out of Repair : Caused by print rollers not being synchronized properly. This results Caused by print rollers not being synchronized properly. This results Caused by print rollers not being synchronized properly. This results in various colors of the design not being printed in the proper position. in various colors of the design not being printed in the proper position. in various colors of the design not being printed in the proper position. Puckered Selvage : Puckered Selvage : Puckered Selvage : Usually caused by selvage being stretched in finishing or by uneven Usually caused by selvage being stretched in finishing or by uneven Usually caused by selvage being stretched in finishing or by uneven wetting out in sanforization process. wetting out in sanforization process. wetting out in sanforization process. Scrimp: Scrimp: Scrimp: Scrip is the result of fabric being folded or creased when passing through tender Scrip is the result of fabric being folded or creased when passing through tender Scrip is the result of fabric being folded or creased when passing through tender frames. frames. frames. Water Spots : Water Spots : Water Spots : Water spots are usually caused by wet fabric being allowed to remain too Water spots are usually caused by wet fabric being allowed to remain too Water spots are usually caused by wet fabric being allowed to remain too long before drying, Color migrates leaving blotchy spots. long before drying, Color migrates leaving blotchy spots. long before drying, Color migrates leaving blotchy spots. Pilling : Pilling : Pilling : Pilling refers to the forming of little matted balls on the surface of knitted fabrics. Pilling refers to the forming of little matted balls on the surface of knitted fabrics. Pilling refers to the forming of little matted balls on the surface of knitted fabrics. Pilling occurs when soft yarn rubs against itself, resulting in tangled fibers and produces an Pilling occurs when soft yarn rubs against itself, resulting in tangled fibers and produces an Pilling occurs when soft yarn rubs against itself, resulting in tangled fibers and produces an uneven and worn look. uneven and worn look. uneven and worn look. 19 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  20. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile CHAPTER – 4 CHAPTER – 4 CHAPTER – 4 Experimental Data Experimental Data Experimental Data 20 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  21. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Raw Materials Raw Materials Raw Materials KNIT CONCERN GROUP KNIT CONCERN GROUP Type Of Yarn used in knit Concern: Type Of Yarn used in knit Concern: Generally used yarn and their count: 24S, 26S, 28S, 30S, 32S, 34S, 40S 75D, 100D 20D,40D, 70D 24S, 26S 24S, 26S, 28S 24S, 26S, 28S, 30S 24S, 26S, 28S, 30S 24S, 26S, 28S, 30S 24S, 26S, 28S, 30S, 32S, 34S, 40S Cotton Polyester Spandex yarn Grey Mélange (C-85% V-15%) Ecru Mélange (C-85% V-1%) PC (65%Polyester & 35% cotton) CVC Grey Mélange (C-85% V-15%) Ecru Mélange (C-85% V-1%) PC (65%Polyester & 35% cotton) 24S, 26S, 28S, 30S Grey Fabrics: Grey Fabrics: Grey Fabrics: Following types of gray fabrics are dyed: Following types of gray fabrics are dyed: Following types of gray fabrics are dyed: 1. Single jersey (All Over print) 2. Single jersey (with Lycra & without Lycra) 3. Polo pique 4. Single lacoste 5. Fleece 6. Interlock (with Lycra & without Lycra) 7. Rib (with Lycra & without Lycra) 8. Different types of collar & cuff Twill tape 9. Terry / Fleece 10. Pointal Rib CHEMICAL LIST CHEMICAL LIST CHEMICAL LIST 1. Single jersey (All Over print) 2. Single jersey (with Lycra & without Lycra) 3. Polo pique 4. Single lacoste 5. Fleece 6. Interlock (with Lycra & without Lycra) 7. Rib (with Lycra & without Lycra) 8. Different types of collar & cuff Twill tape 9. Terry / Fleece 10. Pointal Rib 10. Pointal Rib 1. Single jersey (All Over print) 2. Single jersey (with Lycra & without Lycra) 3. Polo pique 4. Single lacoste 5. Fleece 6. Interlock (with Lycra & without Lycra) 7. Rib (with Lycra & without Lycra) 8. Different types of collar & cuff Twill tape 9. Terry / Fleece Name Of Chemical Antifoam No Name of Item Kappasol AF-2000 AlbafloW FFC Kappavon FCB Argalube NF Kapp Wet BOS Argarep LFD Fabrevol KNN Conc Mescour OSRN Gresaw Turbo Gresaw Turbo Name of Item Kappasol AF-2000 AlbafloW FFC Kappavon FCB Argalube NF Kapp Wet BOS Argarep LFD Fabrevol KNN Conc Mescour OSRN Usage % 0.2 g/l 0.2 g/l 0.8 g/l 0.8 g/l 0.7 g/l 0.7 g/l 0.7 g/l 0.35 g/l 0.35 g/l Name of Company Kapp Chemie GMBH Huntsman Singapore Kapp Chemie GMBH sHanghai xietong (Argus) Kapp Chemie GMBH Shanghai Xietong (Argus) Denimist Matex International Matex International Name of Company Kapp Chemie GMBH Huntsman Singapore Kapp Chemie GMBH sHanghai xietong (Argus) Kapp Chemie GMBH Shanghai Xietong (Argus) Denimist 1 2 3 4 5 6 7 8 9 Anti Crease Ditergent/ Wetting Agent Oil Remover 10 Lanaryl RK Lanaryl RK 0.35 g/l Benevolent Textile service Benevolent Textile service 21 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  22. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Sequestering Agent 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Argaquist ARSK Starquist SD-97 Chelion BD W Argarep CBS StarStab Ex-3 Equa Sec STA Unizyme 1000L MegaPK (CR9) Oxilost P Albatex –DBC Kappkom E-12 Argacel S W Exhaclean BLC Albafix ECO Albafix FRD MeSoft CCS Flacks Softner AWs –P Softner AWs –P Argaquist ARSK Starquist SD-97 Chelion BD W Argarep CBS StarStab Ex-3 Equa Sec STA Unizyme 1000L MegaPK (CR9) Oxilost P Albatex –DBC Kappkom E-12 Argacel S W Exhaclean BLC Albafix ECO Albafix FRD MeSoft CCS Flacks 0.6 g/l 0.6 g/l 0.6 g/l 0.1 g/l 0.1 g/l 0.1 g/l 0.40 g/l 0.40 g/l 0.3 g/l 0.8 g/l 0.5 g/l 0.5 g/l 0.5 g/l sHanghai xietong (Argus) Startech Chemical Veskim Kimyeve sHanghai xietong (Argus) Startech Chemical Veskim Kimyeve Shanghai Youtell Peli-Bio Chem Technology Veskim Kimyeve Huntsman Singapore Kapp Chemie GMBH Shanghai xietong (Argus) Denimist Huntsman Singapore Huntsman Singapore Matex International Taiwan surfactant Taiwan surfactant sHanghai xietong (Argus) Startech Chemical Veskim Kimyeve sHanghai xietong (Argus) Startech Chemical Veskim Kimyeve Shanghai Youtell Peli-Bio Chem Technology Veskim Kimyeve Huntsman Singapore Kapp Chemie GMBH Shanghai xietong (Argus) Denimist Huntsman Singapore Huntsman Singapore Matex International Stabilizer Enzyme Per Oxide Killer Leveling Soaping Agent Fixing Agent Cationic Softener Non ionic Softener 28 Softner E31 Softner E31 0.5 g/l Taiwan surfactant Taiwan surfactant silicon Softener 29 30 31 32 33 34 36 37 KappaSoft-SM wiSifact MCH wiSifact MIC H Invatex Invalon DAM Alpclean (Viscose ) Invatex CRA (Black) Albatex CO (Special Levelling) Rokgent T (M/C waSh ) DEfaten FX (Hit SeT) Gluber Salt Caustic Soda SOda ASh Oxalic Acid Formic Acid KappaTex R98 (Hydroze) Acetic Acid Albatex AB 45 (Buffer) Albatex-AR Eripon OS Ultrafil HSD Univadine DIF Univadine DP Univadine DP KappaSoft-SM wiSifact MCH wiSifact MIC H Invatex Invalon DAM Alpclean (Viscose ) Invatex CRA (Black) Albatex CO (Special Levelling) Rokgent T (M/C waSh ) DEfaten FX (Hit SeT) Gluber Salt Caustic Soda SOda ASh Oxalic Acid Formic Acid KappaTex R98 (Hydroze) Acetic Acid Albatex AB 45 (Buffer) Albatex-AR Eripon OS Ultrafil HSD Univadine DIF Kapp Chemie GMBH VeSkim Kimyeve VeSkim Kimyeve Huntsman Singapore Huntsman Singapore VeSkim Kimyeve Huntsman Singapore Huntsman Singapore Huntsman Singapore Kapp Chemie GMBH VeSkim Kimyeve VeSkim Kimyeve Huntsman Singapore Huntsman Singapore VeSkim Kimyeve Huntsman Singapore Core Neutralizer Fixing Remover Special Chemical 0.5 g/l 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Denge Kimya TeStile Treadasia International Gojrat Hunan Chembrid Indust Mollah Enterprise BASF Kapp Chemie GMBH OCI Corporation Huntsman Singapore Huntsman Singapore Huntsman Singapore Huntsman Singapore Huntsman Singapore Huntsman Singapore Huntsman Singapore Denge Kimya TeStile Treadasia International Gojrat Hunan Chembrid Indust Mollah Enterprise BASF Kapp Chemie GMBH OCI Corporation Huntsman Singapore Huntsman Singapore Huntsman Singapore Huntsman Singapore Huntsman Singapore Basic Chemical 10-80 g/l 1.5-2 g/l 5-17 g/l 1 g/l 1 g/l 2-4 g/l Disperse Chemical 2.3g/l 1 g/l 1 g/l 1 g/l 22 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  23. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile List Of Dyestuff Used for dyeing at knit concern: List Of Dyestuff Used for dyeing at knit concern: Type Of Dye Disperse Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Name Of Dyestuff Teracil Red WW-CBS Teracil Red WW-3BS Teracil Black WNS Teracil Red WWFS Teracil HF2F WBLS Teracil Navy W-RS Teracil Navy GRLC Teracil Red W4BS Teracil Yellow W6BS Synozol Navy Blue HB Synozol Deep Red HB Synozol Yellow HB Synozol Blue K-BR Synozol Turq Blue HF-G 266% Synozol Brill Blue RSCL 150% Amron Navy HR 2D Amron Yellow HR 2D Amron Yellow HF2GL Amron Brill Red HF2R Amron Red HF2F Amron Red HF4BL Amron Blue HR 2D Amtex Yellow 3R- XF Amtex Red 3B- XF Amron Ultra Red HR2D Drimarine Violet K-2RL Drimarine Yellow K-2R HQ4BK Remazol Blue -RR Remazol Yellow -RR Remazol Navy-RR Remazol Ultra Red RGB Remazol Ultra Yellow RGB Reactive Starfix Black –B 150% Reactive Starfix Yellow 3RFN Reactive Starfix Red ED Reactive Starfix Yellow Reactive Starfix 3RFN Reactive Starfix Black ED-HG Name Of Company Huntsman Huntsman Huntsman Huntsman Huntsman Huntsman Huntsman Huntsman Huntsman Kyug-In synthetic Corporation Kyug -In synthetic Corporation Kyug-In synthetic Corporation Kyug-In synthetic Corporation Kyug-In synthetic Corporation Kyug-In synthetic Corporation Amtex Dyechem Amtex Dyechem Amtex Dyechem Amtex Dyechem Amtex Dyechem Amtex Dyechem Amtex Dyechem Amtex Dyechem Amtex Dyechem Amtex Dyechem Clarient Clarient Clarient DyeStar DyeStar DyeStar DyeStar DyeStar DyeStar Hangzhu jihua Import& Export Hangzhu jihua Import& Export Hangzhu jihua Import& Export Hangzhu jihua Import& Export Hangzhu jihua Import& Export Hangzhu jihua Import& Export Hangzhu jihua Import& Export Name Of Company Huntsman Huntsman Huntsman Huntsman Huntsman Huntsman Huntsman Huntsman Huntsman Kyug-In synthetic Corporation Kyug -In synthetic Corporation Kyug-In synthetic Corporation Kyug-In synthetic Corporation Kyug-In synthetic Corporation Kyug-In synthetic Corporation Amtex Dyechem Amtex Dyechem Amtex Dyechem Amtex Dyechem Amtex Dyechem Amtex Dyechem Amtex Dyechem Amtex Dyechem Amtex Dyechem Amtex Dyechem Clarient Clarient Clarient DyeStar DyeStar DyeStar DyeStar DyeStar DyeStar Hangzhu jihua Import& Export Hangzhu jihua Import& Export Hangzhu jihua Import& Export Hangzhu jihua Import& Export Hangzhu jihua Import& Export Teracil Red WW-CBS Teracil Red WW-3BS Teracil Black WNS Teracil Red WWFS Teracil HF2F WBLS Teracil Navy W-RS Teracil Navy GRLC Teracil Red W4BS Teracil Yellow W6BS Synozol Navy Blue HB Synozol Deep Red HB Synozol Yellow HB Synozol Blue K-BR Synozol Turq Blue HF-G 266% Synozol Brill Blue RSCL 150% Amron Navy HR 2D Amron Yellow HR 2D Amron Yellow HF2GL Amron Brill Red HF2R Amron Red HF2F Amron Red HF4BL Amron Blue HR 2D Amtex Yellow 3R- XF Amtex Red 3B- XF Amron Ultra Red HR2D Drimarine Violet K-2RL Drimarine Yellow K-2R HQ4BK Remazol Blue -RR Remazol Yellow -RR Remazol Navy-RR Remazol Ultra Red RGB Remazol Ultra Yellow RGB Reactive Starfix Black –B 150% Reactive Starfix Yellow 3RFN Reactive Starfix Red ED Reactive Starfix Yellow Reactive Starfix 3RFN Reactive Starfix Black ED-HG Reactive Starfix Brill Blue KNR Reactive Starfix Brill Blue KNR Reactive OBA Reactive 23 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  24. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Inspection of Grey Fabric from knitting section to Dyeing: Inspection of Grey Fabric from knitting section to Dyeing:   Checking flow-chart – Checking flow-chart – Knitted fabric (checked in knitting section) Knitted fabric (checked in knitting section) Knitted fabric (checked in knitting section) Grey fabric inspection section for checking by dyeing dept. Grey fabric inspection section for checking by dyeing dept. Grey fabric inspection section for checking by dyeing dept. Checking Checking Checking Ok Ok Ok Not ok Not ok Not ok To storage/ batch section To storage/ batch section To storage/ batch section Recheck Recheck Recheck Dyeing Dyeing Dyeing If not ok, Rejection If not ok, Rejection If not ok, Rejection Checking Standard: Varies depending on buyers’ requirements. For H&M – 4 point system is followed. For others – 10 point system is followed. Frequently found faults: Frequently found faults: Frequently found faults: Checking Standard: Varies depending on buyers’ requirements. For H&M – 4 point system is followed. For others – 10 point system is followed. For others – 10 point system is followed. Checking Standard: Varies depending on buyers’ requirements. For H&M – 4 point system is followed. Loop, Hole, Set-up, Needle, brokenYarn-out, Patty , Patta , Contamination, Lycra-out ,Sinker-mark ,Star-mark ,Wheel-mark, Oil-mark, Groove-mark, Needle-mark, Thick-Thin stripe, Wavy Stripe ,Star-mark ,Wheel-mark, Oil-mark, Groove-mark, Needle-mark, Thick-Thin stripe, Wavy Stripe ,Star-mark ,Wheel-mark, Oil-mark, Groove-mark, Needle-mark, Thick-Thin stripe, Wavy Stripe Loop, Hole, Set-up, Needle, brokenYarn-out, Patty , Patta , Contamination, Lycra-out ,Sinker-mark Loop, Hole, Set-up, Needle, brokenYarn-out, Patty , Patta , Contamination, Lycra-out ,Sinker-mark Knit Dyeing Operation process : Knit Dyeing Operation process : Knit Dyeing Operation process : General process for Dyeing General process for Dyeing General process for Dyeing  Auxiliaries are added at 50° C  Salt added by dosing system ( time : 10-20')  pH maintained at 6.5-7  Color dosing at 6O° C for 20' Exhaustion & Fixation :  After 30' soda ash added by dosing for 30-35'  pH checked & maintained at 10.5  Dye bath is kept at 60° C for 40-60'  After every 10' the sample is checked fixation occurs during this time.  Rinse for 10' & the bath is drained.  Rinse for 10' & the bath is drained.  Rinse for 10' & the bath is drained.  Auxiliaries are added at 50° C  Salt added by dosing system ( time : 10-20')  pH maintained at 6.5-7  Color dosing at 6O° C for 20' Exhaustion & Fixation :  After 30' soda ash added by dosing for 30-35'  pH checked & maintained at 10.5  Dye bath is kept at 60° C for 40-60'  After every 10' the sample is checked fixation occurs during this time.  After every 10' the sample is checked fixation occurs during this time.  Auxiliaries are added at 50° C  Salt added by dosing system ( time : 10-20')  pH maintained at 6.5-7  Color dosing at 6O° C for 20' Exhaustion & Fixation :  After 30' soda ash added by dosing for 30-35'  pH checked & maintained at 10.5  Dye bath is kept at 60° C for 40-60' 24 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  25. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Neutralization : Neutralization : Neutralization :  The material should be neutralized to remove alkaline condition at room temperature by acid wash for 15 min & rinsing will be carried on for 10 min. temperature by acid wash for 15 min & rinsing will be carried on for 10 min. temperature by acid wash for 15 min & rinsing will be carried on for 10 min.  The material should be neutralized to remove alkaline condition at room  The material should be neutralized to remove alkaline condition at room Soaping : Soaping : Soaping :  Then soaping agent is added & temperature raised to 90°¬100°C for 10 min.  The bath is cooled 7 rinsed for 10 min.  Dye bath temperature then cooled to 60° C.  Dye bath temperature then cooled to 60° C.  Dye bath temperature then cooled to 60° C.  Then soaping agent is added & temperature raised to 90°¬100°C for 10 min.  The bath is cooled 7 rinsed for 10 min.  The bath is cooled 7 rinsed for 10 min.  Then soaping agent is added & temperature raised to 90°¬100°C for 10 min. Softening: Softening: Softening:  Softener is applied to soften the fabric as well as it improves the hand feel. The material is treated at 60°C for 20 mins. Then rinsing again & material unload. material is treated at 60°C for 20 mins. Then rinsing again & material unload. material is treated at 60°C for 20 mins. Then rinsing again & material unload.  Softener is applied to soften the fabric as well as it improves the hand feel. The  Softener is applied to soften the fabric as well as it improves the hand feel. The Dyeing Process / Program of knit Concern Group: Dyeing Process / Program of knit Concern Group: Dyeing Process / Program of knit Concern Group: 1. Isothermal ( Medium Brand Avg. Color-600c ) 2. Green Isothermal ( HOT Brand Dye – 800c ) 3. Black CRA HOT ( For Black Color –without Bleach ,Only scouring with Cracking Agent ) 4. Any White Process (For 10-100 Shade ) 5. Scouring Enzyme (For Gray Mélange) 6. Light and Medium 7. CVC 2 Part Dyeing (For PC/CVC Blanding) 8. RGB Process (For Remazol Dye –Dark Shade ) 9. RR Process (For Remazol Dye –Light Shade) 10. Special Turquoise (For Greenish Shade Where Turquoise% > 1%) 11. Yarn dyed Wash (Yarn Dyed Stripe Fabric ) 12. R Special (RSPL) Process (For Reactive Starfix Brill Blue KNR & Synozol Brill Blue RSCL 150%) 13. DK 15-10-2012 (Navy & Brown Shade) 14. Light Color (If Shade% < .5%) 15. 1350x 45’ (Only Polymer Part) 16. Slub White (Demineralization Of Cotton Slub By Core neutralizer Oxalic Acid ) 17. Lycra White (Demineralization Of Lycra Lubrication ) 18. CVC Cotton Part (Only Cotton Part) 19. Machine Wash (If Transfer Deep To Light Shade ) 20. Stripping (If Color not Ok) 20. Stripping (If Color not Ok) 20. Stripping (If Color not Ok) 1. Isothermal ( Medium Brand Avg. Color-600c ) 2. Green Isothermal ( HOT Brand Dye – 800c ) 3. Black CRA HOT ( For Black Color –without Bleach ,Only scouring with Cracking Agent ) 4. Any White Process (For 10-100 Shade ) 5. Scouring Enzyme (For Gray Mélange) 6. Light and Medium 7. CVC 2 Part Dyeing (For PC/CVC Blanding) 8. RGB Process (For Remazol Dye –Dark Shade ) 9. RR Process (For Remazol Dye –Light Shade) 10. Special Turquoise (For Greenish Shade Where Turquoise% > 1%) 11. Yarn dyed Wash (Yarn Dyed Stripe Fabric ) 12. R Special (RSPL) Process (For Reactive Starfix Brill Blue KNR & Synozol Brill Blue RSCL 150%) 13. DK 15-10-2012 (Navy & Brown Shade) 14. Light Color (If Shade% < .5%) 15. 1350x 45’ (Only Polymer Part) 16. Slub White (Demineralization Of Cotton Slub By Core neutralizer Oxalic Acid ) 17. Lycra White (Demineralization Of Lycra Lubrication ) 18. CVC Cotton Part (Only Cotton Part) 19. Machine Wash (If Transfer Deep To Light Shade ) 19. Machine Wash (If Transfer Deep To Light Shade ) 1. Isothermal ( Medium Brand Avg. Color-600c ) 2. Green Isothermal ( HOT Brand Dye – 800c ) 3. Black CRA HOT ( For Black Color –without Bleach ,Only scouring with Cracking Agent ) 4. Any White Process (For 10-100 Shade ) 5. Scouring Enzyme (For Gray Mélange) 6. Light and Medium 7. CVC 2 Part Dyeing (For PC/CVC Blanding) 8. RGB Process (For Remazol Dye –Dark Shade ) 9. RR Process (For Remazol Dye –Light Shade) 10. Special Turquoise (For Greenish Shade Where Turquoise% > 1%) 11. Yarn dyed Wash (Yarn Dyed Stripe Fabric ) 12. R Special (RSPL) Process (For Reactive Starfix Brill Blue KNR & Synozol Brill Blue RSCL 150%) 13. DK 15-10-2012 (Navy & Brown Shade) 14. Light Color (If Shade% < .5%) 15. 1350x 45’ (Only Polymer Part) 16. Slub White (Demineralization Of Cotton Slub By Core neutralizer Oxalic Acid ) 17. Lycra White (Demineralization Of Lycra Lubrication ) 18. CVC Cotton Part (Only Cotton Part) Production parameters of Knit Dyeing : a. pH: a. pH: a. pH: Production parameters of Knit Dyeing : Production parameters of Knit Dyeing : During H2O2 bleaching During reactive dyeing During disperse dyeing During Leveling During Salt During Soda During Soda During H2O2 bleaching During reactive dyeing During disperse dyeing During Leveling During Salt pH 9 – 11 pH 10.5 – 12 pH 4.5 – 5.5 pH 5.5 – 6.0 pH 6.0 – 6.5 pH 10.5-11.5 pH 10.5-11.5 pH 9 – 11 pH 10.5 – 12 pH 4.5 – 5.5 pH 5.5 – 6.0 pH 6.0 – 6.5 25 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  26. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile During Soaping During Dye bath During Softener During Fixing During Fixing During Soaping During Dye bath During Softener pH 6.0 – 6.5 pH 10.5 – 11.5 pH 4.5 – 5.0 pH 5 .0 – 5.5 pH 5 .0 – 5.5 pH 6.0 – 6.5 pH 10.5 – 11.5 pH 4.5 – 5.0 b. Temperature: b. Temperature: For cotton scouring 900-950C For cotton Enzyme wash 550C For cotton cold wash 300– 400C For cotton hot wash 700-800C For cotton acid wash 600-700C For cotton dyeing For cotton dyeing For cotton dyeing Polyester dyeing: Polyester dyeing: For cotton scouring 900-950C For cotton Enzyme wash 550C For cotton cold wash 300– 400C For cotton hot wash 700-800C For cotton acid wash 600-700C For cotton dyeing For cotton dyeing For cotton dyeing For cotton dyeing 800-900C ( For hot brand ) 600C ( For Medium brand ) 800C ( For Turquoise/ Blue RSPCL/CNR ) 1000-1300C 1000-1300C 800-900C ( For hot brand ) 600C ( For Medium brand ) 800C ( For Turquoise/ Blue RSPCL/CNR ) 800C ( For Turquoise/ Blue RSPCL/CNR ) c. Time: c. Time: For scouring 60-90 mins For reactive dyeing 60-90 mins For disperse dyeing 60-90 mins For Enzyme treatment 60-90 mins For Enzyme treatment 60-90 mins For scouring 60-90 mins For reactive dyeing 60-90 mins For disperse dyeing 60-90 mins d. M:L ratio: d. M:L ratio: For reactive dyeing M:L ration maintained For reactive dyeing M:L ration maintained For reactive dyeing M:L ration maintained 1 : 3 ( polyester - Airflow Dyeing ) 1 : 4 ( Cotton- Airflow Dyeing ) 1 : 6 ( Lab-Knit Dyeing/Yarn Dyeing) 1 : 6 ( Bulk Yarn Dyeing ) 1 : 7 ( Pretreatment /washing ) 1 : 8 ( Knit Dyeing – Atm/HTHP ) 1 : 8 ( Knit Dyeing – Atm/HTHP ) 1 : 8 ( Knit Dyeing – Atm/HTHP ) 1 : 3 ( polyester - Airflow Dyeing ) 1 : 4 ( Cotton- Airflow Dyeing ) 1 : 6 ( Lab-Knit Dyeing/Yarn Dyeing) 1 : 6 ( Bulk Yarn Dyeing ) 1 : 7 ( Pretreatment /washing ) 1 : 7 ( Pretreatment /washing ) 1 : 3 ( polyester - Airflow Dyeing ) 1 : 4 ( Cotton- Airflow Dyeing ) 1 : 6 ( Lab-Knit Dyeing/Yarn Dyeing) 1 : 6 ( Bulk Yarn Dyeing ) e. Pressure: e. Pressure: e. Pressure: kg/cm2G kg/cm2G Steam pressure : 5 – 6 Water pressure : 1.2 – 2 kg/cm2G Air pressure : 5 – 7 Air pressure : 5 – 7 Air pressure : 5 – 7 Steam pressure : 5 – 6 Water pressure : 1.2 – 2 kg/cm2G kg/cm2 kg/cm2 kg/cm2 General Parameters of Dyeing machines:  Capacity per nozzle:theoretically 250 kg but practically not more than 200 kg should be used.  Nozzle pressure: 4-6 psi  Steam pressure: 7 bar (inlet of heat exchanger)  Cold water temp. & pressure: 25 c & 3 bar  Maximum temp. : 140 for high temp. M/c : 100 for atmospheric  Reel/Winch speed: 150-250 rpm/450- JamboTech  Main motor efficiency: 80-85% (Loding)  Main motor efficiency: 80-85% (Loding)  Main motor efficiency: 80-85% (Loding) General Parameters of Dyeing machines:  Capacity per nozzle:theoretically 250 kg but practically not more than 200 kg should be used.  Nozzle pressure: 4-6 psi  Steam pressure: 7 bar (inlet of heat exchanger)  Cold water temp. & pressure: 25 c & 3 bar  Maximum temp. : 140 for high temp. M/c : 100 for atmospheric  Reel/Winch speed: 150-250 rpm/450- JamboTech  Reel/Winch speed: 150-250 rpm/450- JamboTech General Parameters of Dyeing machines:  Capacity per nozzle:theoretically 250 kg but practically not more than 200 kg should be used.  Nozzle pressure: 4-6 psi  Steam pressure: 7 bar (inlet of heat exchanger)  Cold water temp. & pressure: 25 c & 3 bar  Maximum temp. : 140 for high temp. M/c : 100 for atmospheric 26 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  27. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Machine Model : Machine Model : 1. Fongs HJ (2T, 1T, 8T, 4T) 2. Fongs Jambo Tech 3 (2T) 3. Fongs Eco 6 (2T) 4. Fongs GN6 SR 5. Fongs Allfit (60,10,5) 6. Fongs ECO (4T,6T,1T) 7. THEN (Synergy 1x AFS 450 , 225, 775 ,1350 ) 7. THEN (Synergy 1x AFS 450 , 225, 775 ,1350 ) 1. Fongs HJ (2T, 1T, 8T, 4T) 2. Fongs Jambo Tech 3 (2T) 3. Fongs Eco 6 (2T) 4. Fongs GN6 SR 5. Fongs Allfit (60,10,5) 6. Fongs ECO (4T,6T,1T) Machine List: Machine List: M/C No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 TYPE TYPE BRAND BRAND MC. QTY. 47 Nos. 08 Nos. 02 Nos. 01 Nos. 01 Nos. 01 Nos. 01 Nos. 03 Nos. 01 Nos. 01 Nos. 03 Nos. 01 Nos. 03 Nos. 02 Nos. 01 Nos. 01 Nos. 01 Nos. 05 Nos. Dyeing machine Dyeing machine (Airflow ) Dewatering & Detwisting MC. Dewatering & Detwisting MC. Efficient shrinkage Dryer Santashrink jumbo Dryer Shrink Control Dryer Compactor (Tubler) Open Width Compactor Open Width Compactor Slitting Machine Stenter Stenter Sueding Machine Brushing Machine Shearing Machine Singeing Machine Turning Machine Turning Machine Dyeing machine Dyeing machine (Airflow ) Dewatering & Detwisting MC. Dewatering & Detwisting MC. Efficient shrinkage Dryer Santashrink jumbo Dryer Shrink Control Dryer Compactor (Tubler) Open Width Compactor Open Width Compactor Slitting Machine Fong’s THEN Santex Bianco Fong’s Santex BRIO Tube-Tex Tube-Tex Bruckner Bianco Tube-Tex Bruckner Lafer Gematex Gematex Osthoff Puji/Hsing Cheng/Daroitex GMT Dong Nang Sueding Machine Brushing Machine Shearing Machine Singeing Machine 19 20 Back Sewing Machine Steam Setting Machine Steam Setting Machine Back Sewing Machine 03 Nos. 02 Nos. 21 22 Grey Fabric Check Machine Finish Fabric Check Machine Finish Fabric Check Machine Grey Fabric Check Machine UZU Daroitex/HsingCheng Daroitex/HsingCheng 09 Nos. 05 Nos. Total Machine :- Total Machine :- 102 Nos. 27 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  28. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Description of Different Finishing Machines Description of Different Finishing Machines Description of Different Finishing Machines DRYER DRYER Manufacturer Manufacturer : : SANTEX, FONG’S, FONG’S, SANTEX, SWITZERLAND(1 Nos.). HONGKONG(1 Nos.). HONGKONG(1 Nos.). SWITZERLAND(1 Nos.). Technical Parameters: Temperature  Temperature Technical Parameters: For colored fabric – Chamber 1 – 140c For colored fabric – Chamber 1 – 140c : :  Chamber 2 – 150c Chamber 3 – 130c Chamber 3 – 130c Chamber 3 – 130c Chamber 2 – 150c Chamber 2 – 150c For White (bleached) - all chambers - 120c 3000 mm 8-80 m/min 35-55 mm 140 kw 140 kw For White (bleached) - all chambers - 120c 3000 mm 8-80 m/min 35-55 mm For White (bleached) - all chambers - 120c 3000 mm Working width Speed Nozzle distance Power consumption: Power consumption: Working width Speed Nozzle distance Working width : : : : : : :          TUBE COMPACTOR Manufacturer Technical Parameters Speed of passing fabric Shaper length Overfeed ratio  Overfeed ratio TUBE COMPACTOR Manufacturer Technical Parameters Speed of passing fabric Shaper length : : TUBETEX, USA(3 Nos.). TUBETEX, USA(3 Nos.). 22-40 m/min according to required Dia Edge drive zone – 1.0-1.5 Retard roller – 0.80-0.85 Take-out zone – 0.85-0.90 Conveyor belt – 1.0-1.05 Plaiter – 0.80-0.85 according to Shrinkage result S/J – 10-15% Rib – 10-12% Interlock – 8-10% Pique – 7-8% S/J – large dia – avg. 30 psi S/J – smaller dia – 10-15 psi Rib – 10-20 psi Lycra - <10 psi 80 kw 90c 90c : : : : 22-40 m/min according to required Dia Edge drive zone – 1.0-1.5 Retard roller – 0.80-0.85 Take-out zone – 0.85-0.90 Conveyor belt – 1.0-1.05 Plaiter – 0.80-0.85 according to Shrinkage result S/J – 10-15% Rib – 10-12% Interlock – 8-10% Pique – 7-8% S/J – large dia – avg. 30 psi S/J – smaller dia – 10-15 psi Rib – 10-20 psi Lycra - <10 psi 80 kw 80 kw : :      Retard roller – 0.80-0.85 Take-out zone – 0.85-0.90 Conveyor belt – 1.0-1.05 Plaiter – 0.80-0.85 according to Shrinkage result Compaction% Compaction% Compaction% : : :    Shoe pressure Shoe pressure : :   S/J – smaller dia – 10-15 psi Rib – 10-20 psi Lycra - <10 psi Power consumed Thermo-Oil temperature Thermo-Oil temperature Power consumed Power consumed : : : : :      28 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  29. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile STENTER STENTER Manufacturer Technical Parameters Working Width Total Length Padder Pressure  Padder Pressure  Padder Pressure Manufacturer Technical Parameters Working Width Total Length : : BRUKNER, GERMANY (3 Nos.) BRUKNER, GERMANY (3 Nos.) : : : : : : : 600-2600 mm 138 ft Max. air Pressure – 10 bar (avg. 5-7) Max. Steam Pressure – 0.7 bar Back Zone – 0-5 Master overfeed – 80% (in case of heat-set 15-20%) Wheel overfeed – 3% Feed overfeed – 3-5% Take-up overfeed – 15-20% Normal – 130-150c Heat-Set – 180-210c Normally 35-40 m/min Heat set 18-22 m/min S/j +1-2 inches Interlock/Rib - 1% Lycra +8-10% White, Color, Silicon Softener White, Color, Silicon Softener 600-2600 mm 138 ft Max. air Pressure – 10 bar (avg. 5-7) Max. Steam Pressure – 0.7 bar Back Zone – 0-5 Master overfeed – 80% (in case of heat-set 15-20%) Wheel overfeed – 3% Feed overfeed – 3-5% Take-up overfeed – 15-20% Normal – 130-150c Heat-Set – 180-210c Normally 35-40 m/min Heat set 18-22 m/min S/j +1-2 inches Interlock/Rib - 1% Lycra +8-10%     Max. air Pressure – 10 bar (avg. 5-7)  Overfeed Ratio Overfeed Ratio : :   Master overfeed – 80% (in case of heat-set 15-20%) Wheel overfeed – 3% Feed overfeed – 3-5% Take-up overfeed – 15-20% Normal – 130-150c Temperature Temperature Temperature : : :    Speed of Passing Fabric Speed of Passing Fabric : :   Width Controlling Width Controlling : :   Types of Softener used Types of Softener used : :   Parameters used for different types of fabric: Parameters used for different types of fabric: BRUCKNER Fabric Req. GSM 140 160 180 190 280 280 Finish GSM - 150/52 170/72 188/90 270/75 255/60 R R F B Temperature Speed m/min 14 20 12 15 7 9 Over feed S/J ” ” “ H/J Loop back Fleece 1×1 rib Bolton stripe 68” 56” 54” 58” 64” 74” 74” 68” 56” 54” 58” 64” 71” 64” 56” 61” 67” 78” 67” 60” 54.5” 57” 62” 75” 140 150 110 110 110 110 80% 80% 60% 80% 80% 80% 260 240 330 260/65 224/26 340/45 74” 72” 62” 62” 74” 72” 80” 75” 67” 75” 74” 65” 110 110 130 9 10 10 80% 80% 80% 29 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  30. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile CHAPTER -3 CHAPTER -3 CHAPTER -3 DATA ANALYSIS DATA ANALYSIS DATA ANALYSIS 30 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  31. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Gray Fabric Faults Gray Fabric Faults Gray Fabric Faults Causes Causes Remedies Image Fault name 1. Yarn strength must be sufficient to withstand the stretch as well as uniform. 1. Yarn breakage or yarn cracks. 2. If the yarn count is not correct on regarding structure, gauge, course and density. 3. Badly knot or splicing. 4. Yarn feeder badly set. 5. If yarn tension too high 5. If yarn tension too high 1. Yarn breakage or yarn cracks. 2. If the yarn count is not correct on regarding structure, gauge, course and density. 3. Badly knot or splicing. 4. Yarn feeder badly set. Hole Mark 2. Use proper count of yarn. 3. Correctly set of yarn feeder. 4. Knot should be given properly 1.When a needle breaks down. 2. If a needle or needle hook is slightly bends . 3. If needle does not catch yarn . yarn . 1.When a needle breaks down. 2. If a needle or needle hook is slightly bends . 3. If needle does not catch 1. Needle should be straight as well as from broken latch. Needle Mark 1. Yarn tension variation during production. during production. 1. Yarn tension variation 1. Maintain same Yarn tension during production. 2. 2. Buckling of the needle latch. latch. Buckling of the needle Star Mark 2. Use good conditioned needles. 3. 3. Low G.S.M fabric production production Low G.S.M fabric 31 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  32. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Fault Name Cause Remedies Image 1. Defective needle. 1. Defective needle. 1.Needle should be straight & well. 2.If yarn is not properly fed during loop formation i.e. not properly laid on to the needle hook. the needle hook. 2.If yarn is not properly fed during loop formation i.e. not properly laid on to 2. Proper feeding of yarn during loop formation. 3.Correct take up of the fabric & correct tension. Drop Stitches 3.Take-down mechanism too loose. too loose. 3.Take-down mechanism fabric 4. Insufficient yarn tension. 5.Badly set yarn feeder. 5.Badly set yarn feeder. 4. Insufficient yarn tension. 4. Yarn tension should be properly. 1. remove irregular yarn 1. Use of irregular yarn having higher long term irregularities. irregularities. 1. Use of irregular yarn having higher long term 2. use proper yarn count Bariness 3.we can use it for white fabric 2. Using different count thread. thread. 2. Using different count 1. If needle latch is hard or curve. or curve. 1. If needle latch is hard 1. clean or change the needle. Loop 2. 2. 2. set proper yarn tension if yarn tension is loose . . if yarn tension is loose 32 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  33. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Fault Name Cause Remedies Image Cause by If lycra is missed or Lycra attach with the yarn yarn Cause by If lycra is missed or Lycra attach with the Check the feeder and attatch laycra. Lycra out 1. 1. if needle latch is not work properly/jaum properly/jaum if needle latch is not work Seat up (cloth fallout) Make sure all the latches of needle are closed with feeding yarn after a drop stitch. 2. Causes by thick yarn 2. Causes by thick yarn 3. Improper/large knot 3. Improper/large knot 1. Ensure that oil does not pass on the fabrics. 1. Excessive oil flow in the needle the needle 1. Excessive oil flow in Oil mark 2. Well maintenance as well as proper oiling. 2. Leakage of oil line 2. Leakage of oil line 33 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  34. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Image Fault Name Cause Remedies 1. Blowing air for cleaning and different parts after a certain period of time. 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. fabric production. 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 2. By cleaning the floor Continuously. Fly 3. By using ducting system for cleaning too much lint in the floor. 4. Over all ensure that lint does not attach to the fabric 1. 1. If yarn contains foreign fiber then it remains in the fabric even after finishing, even after finishing, If yarn contains foreign fiber then it remains in the fabric 1. By avoiding lot, count mixing. Yarn contamin- ation 2. Fault less spinning. 2. If lot, count mixing occurs occurs 2. If lot, count mixing 1. When sinker corrode due to abrasion then some times can not hold a new loop as a result sinker mark comes. sinker mark comes. 1. When sinker corrode due to abrasion then some times can not hold a new loop as a result Sinker should be changed Sample Not Found Sinker Mark 2. If sinker head bend then sinker mark comes comes 2. If sinker head bend then sinker mark 34 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  35. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile PRETREATMENT FAULTS PRETREATMENT FAULTS PRETREATMENT FAULTS Problem: Entanglement of fabrics Problem: Entanglement of fabrics Problem: Entanglement of fabrics Sources & Causes:  Very less jet-pressure, over loading of fabrics, causing fabric tube to “Jam” in front of the machine, making it difficult for the winch to lift and transport the fabric.  Too high jet pressure also leads to entanglement at the reel and accumulation of fabric at the rear side of the machine.  Foaming due to the presence of lubricants used for knitting or due to surfactants / wetting agents that has more foaming properties. Remedies:  Adjust the jet pressure, calculate weight of the fabric to be loaded based on the rope length, diameter of the tube & gsm.  Always load the fabric at warm after adding antcrease Liq. For foams due to impurities (lubricants, wax),antifoam based on non-silicone chemicals are recommended, Check the filter and clean before dyeing and pretreatment. filter and clean before dyeing and pretreatment. filter and clean before dyeing and pretreatment. Sources & Causes:  Very less jet-pressure, over loading of fabrics, causing fabric tube to “Jam” in front of the machine, making it difficult for the winch to lift and transport the fabric.  Too high jet pressure also leads to entanglement at the reel and accumulation of fabric at the rear side of the machine.  Foaming due to the presence of lubricants used for knitting or due to surfactants / wetting agents that has more foaming properties. Remedies:  Adjust the jet pressure, calculate weight of the fabric to be loaded based on the rope length, diameter of the tube & gsm.  Always load the fabric at warm after adding antcrease Liq. For foams due to impurities (lubricants, wax),antifoam based on non-silicone chemicals are recommended, Check the (lubricants, wax),antifoam based on non-silicone chemicals are recommended, Check the Sources & Causes:  Very less jet-pressure, over loading of fabrics, causing fabric tube to “Jam” in front of the machine, making it difficult for the winch to lift and transport the fabric.  Too high jet pressure also leads to entanglement at the reel and accumulation of fabric at the rear side of the machine.  Foaming due to the presence of lubricants used for knitting or due to surfactants / wetting agents that has more foaming properties. Remedies:  Adjust the jet pressure, calculate weight of the fabric to be loaded based on the rope length, diameter of the tube & gsm.  Always load the fabric at warm after adding antcrease Liq. For foams due to impurities Knit Dyeing and and Pretreatment machine for scouring and bleaching At Knit Concern Group At Knit Concern Group At Knit Concern Group Knit Dyeing and and Pretreatment machine for scouring and bleaching Knit Dyeing and and Pretreatment machine for scouring and bleaching 35 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  36. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Problem: Oil marks on fabrics Problem: Oil marks on fabrics 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 oil or lubricant used. The quantity of such oil/lubricant on the fabric can be more because of splashing of oil due to unexpected machinery problems or due to irregularity of yarn.  Improper housekeeping and handling of rolls. rolls. rolls. Sources & Causes:  If the fabric is stored for more than a week,it may oxidise depending on the quality of knitting oil or lubricant used. The quantity of such oil/lubricant on the fabric can be more because of splashing of oil due to unexpected machinery problems or due to irregularity of yarn.  Improper housekeeping and handling of  Improper housekeeping and handling of Sources & Causes:  If the fabric is stored for more than a week,it may oxidise depending on the quality of knitting oil or lubricant used. The quantity of such oil/lubricant on the fabric can be more because of splashing of oil due to unexpected machinery problems or due to irregularity of yarn. Remedies:     Remedies:   Remedies: Use KNIT lubricating agent while knitting. Oxidised oil marks are removed by special scouring with 1.0-2.0% Sandoclean ® PC/PCJ Liq., 0.75 -1.5% Imerol® SR Liq. Boil, 30 min. at pH 9.0 followed by rinsing after neutralising. Lab pretrials are required before proceeding to bulk to find out optimum dosage quantity. quantity. quantity. Use KNIT lubricating agent while knitting. Oxidised oil marks are removed by special scouring with 1.0-2.0% Sandoclean ® PC/PCJ Liq., 0.75 -1.5% Imerol® SR Liq. Boil, 30 min. at pH 9.0 followed by rinsing after neutralising. Lab pretrials are required before proceeding to bulk to find out optimum dosage Lab pretrials are required before proceeding to bulk to find out optimum dosage Use KNIT lubricating agent while knitting. Oxidised oil marks are removed by special scouring with 1.0-2.0% Sandoclean ® PC/PCJ Liq., 0.75 -1.5% Imerol® SR Liq. Boil, 30 min. at pH 9.0 followed by rinsing after neutralising.    Problem: End-marks Problem: End-marks Problem: End-marks Sources & Causes:  Remedies:    Sources & Causes:   Remedies: Sources & Causes: If fabric rolls are stored on their ends, knitted fabrics are prone to get “End Marks”. If fabric rolls are stored on their ends, knitted fabrics are prone to get “End Marks”. Remedies: Store & transport the fabric horizontally, in suitable plastic or cloth bags. Store & transport the fabric horizontally, in suitable plastic or cloth bags. If fabric rolls are stored on their ends, knitted fabrics are prone to get “End Marks”. Store & transport the fabric horizontally, in suitable plastic or cloth bags. Problem: Uneven surface appearance particularly on interlock fabric Problem: Uneven surface appearance particularly on interlock fabric Problem: Uneven surface appearance particularly on interlock fabric Sources & Causes:  This problem mainly occurs when the grey cotton quality is poor.  Too high mechanical stress on the fabric results in pilling or metal to fabric and fabric to fabric frictions.  Too much fluff formation on the fabric, because of bad running properties created, action of alkali & low cost solvent based wetting agents.  Long duration of running due to reprocessing  Long duration of running due to reprocessing  Long duration of running due to reprocessing Sources & Causes:  This problem mainly occurs when the grey cotton quality is poor.  Too high mechanical stress on the fabric results in pilling or metal to fabric and fabric to fabric frictions.  Too much fluff formation on the fabric, because of bad running properties created, action of alkali & low cost solvent based wetting agents. of alkali & low cost solvent based wetting agents. Sources & Causes:  This problem mainly occurs when the grey cotton quality is poor.  Too high mechanical stress on the fabric results in pilling or metal to fabric and fabric to fabric frictions.  Too much fluff formation on the fabric, because of bad running properties created, action Remedies:    Remedies: Remedies: Fabric may be singed to remove the protruding fibres. Fabric may be singed to remove the protruding fibres. Fabric may be singed to remove the protruding fibres. 36 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  37. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile    To reduce the compromising speed during scouring & washing. (i.e. r unning at optimum speed depending on machine type) Use of Lubricants and softener Clariant’s BIO-BLEACH concept gives best results without too much fluff Clariant’s BIO-BLEACH concept gives best results without too much fluff Clariant’s BIO-BLEACH concept gives best results without too much fluff To reduce the To reduce the compromising speed during scouring & washing. (i.e. r unning at optimum speed depending on machine type) hydro mechanical action on the fabric, machine can be run at a hydro mechanical action on the fabric, machine can be run at a compromising speed during scouring & washing. (i.e. r unning at optimum speed depending on machine type) Use of Lubricants and softener Use of Lubricants and softener hydro mechanical action on the fabric, machine can be run at a       Problem: Ballooning of tubular knits of heavy texture fabrics Problem: Ballooning of tubular knits of heavy texture fabrics Problem: Ballooning of tubular knits of heavy texture fabrics Sources & Causes: Sources & Causes: Sources & Causes:    If the pieces are densely sewn & the structure of knit patter n is tight, the entrapped air cannot go out & results in ballooning which in turn leads to entanglement. air cannot go out & results in ballooning which in turn leads to entanglement. air cannot go out & results in ballooning which in turn leads to entanglement. If the pieces are densely sewn & the structure of knit patter n is tight, the entrapped If the pieces are densely sewn & the structure of knit patter n is tight, the entrapped Remedies: Remedies: Remedies:          By cutting a vertical slit of 10-15cm near the joint of two tubes enables the air to escape. The use of larger diameter nozzle will also minimize the problem. Addition of deaerating & penetrating agent (Sandozin® NA Liq.) can be added as a safety measure. measure. measure. By cutting a vertical slit of 10-15cm near the joint of two tubes enables the air to escape. The use of larger diameter nozzle will also minimize the problem. Addition of deaerating & penetrating agent (Sandozin® NA Liq.) can be added as a safety Addition of deaerating & penetrating agent (Sandozin® NA Liq.) can be added as a safety By cutting a vertical slit of 10-15cm near the joint of two tubes enables the air to escape. The use of larger diameter nozzle will also minimize the problem. Problem: Poor absorbency of fabrics after scouring / Peroxide boil Problem: Poor absorbency of fabrics after scouring / Peroxide boil Problem: Poor absorbency of fabrics after scouring / Peroxide boil Sources & Causes:    Sources & Causes: Sources & Causes: Presence of Ca & Mg salts on fabric and in water leading to precipitation in alkali and redeposition thereof. Due to the use of poor quality of wetting agents which have low alkali stability, and hence cannot assist the penetration of Caustic Soda for efficient saponification reaction. Because of poor detergency and dispersing effects, paraffin wax cannot be removed completely. Redeposition of Oil / Wax. Redeposition of Oil / Wax. Redeposition of Oil / Wax. Presence of Ca & Mg salts on fabric and in water leading to precipitation in alkali and redeposition thereof. Due to the use of poor quality of wetting agents which have low alkali stability, and hence cannot assist the penetration of Caustic Soda for efficient saponification reaction. Because of poor detergency and dispersing effects, paraffin wax cannot be removed completely. removed completely. Presence of Ca & Mg salts on fabric and in water leading to precipitation in alkali and redeposition thereof. Due to the use of poor quality of wetting agents which have low alkali stability, and hence cannot assist the penetration of Caustic Soda for efficient saponification reaction. Because of poor detergency and dispersing effects, paraffin wax cannot be       Remedies: Remedies: Remedies:    Protonic pretreatment before scouring gives an outstanding cleaning effect. Heavy weight fabrics: Sirrix® YK Liq 2.0g/l Sandoclean® LFD Liq. 0.5g/l 80°C, 30 min, Rinse hot 80°C, 30 min, Rinse hot Protonic pretreatment before scouring gives an outstanding cleaning effect. Heavy weight fabrics: Sirrix® YK Liq 2.0g/l Sandoclean® LFD Liq. 0.5g/l Protonic pretreatment before scouring gives an outstanding cleaning effect. Light weight fabrics: Sirrix® 2UDI Liq. Sandoclean® PCJ Liq. 0.5g/l 60°C, 30 min, Rinse Light weight fabrics: Sirrix® 2UDI Liq. Sandoclean® PCJ Liq. 0.5g/l 1-2g/l 1-2g/l    Use of Sandoclean® PCJ Liq. is recommended as a wetting agent. The synergistic properties of the product helps to penetrate into the core of the fibre by eliminating fibre-liquid surface tension, and saponification of all impurities. So, fabrics obtain very good absorbency. good absorbency. good absorbency. Use of Sandoclean® PCJ Liq. is recommended as a wetting agent. The synergistic properties of the product helps to penetrate into the core of the fibre by eliminating fibre-liquid surface tension, and saponification of all impurities. So, fabrics obtain very fibre-liquid surface tension, and saponification of all impurities. So, fabrics obtain very Use of Sandoclean® PCJ Liq. is recommended as a wetting agent. The synergistic properties of the product helps to penetrate into the core of the fibre by eliminating 37 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  38. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Problem: Tendering of fabric during bleaching Sources & Causes:  The presence of iron on the fabric acts as a decomposition catalyst for H2O2. In a freely circulating bath new sources of iron oxides form, as a chain reaction of homolytic cleavage of H2O2into hydroxide radicals which attacks cellulose to form oxycellulose. Remedies:  Addition of Sirrix® 2UDI Liq. In Peroxide bleach bath or by one step combined protonic pretreatment & scouring. (Sandoclean® PCJ Liq. 0.5g/l 60°C, Sirrix 2UDI Liq. 1g/l 20min)Then continue peroxide bleach in the same bath. Addition of Stabilizer® SIFAM Liq. Also prevents the formation of atomic oxygen responsible for cellulose damage. Liq. Also prevents the formation of atomic oxygen responsible for cellulose damage. Liq. Also prevents the formation of atomic oxygen responsible for cellulose damage. Problem: Tendering of fabric during bleaching Sources & Causes:  The presence of iron on the fabric acts as a decomposition catalyst for H2O2. In a freely circulating bath new sources of iron oxides form, as a chain reaction of homolytic cleavage of H2O2into hydroxide radicals which attacks cellulose to form oxycellulose. Remedies:  Addition of Sirrix® 2UDI Liq. In Peroxide bleach bath or by one step combined protonic pretreatment & scouring. (Sandoclean® PCJ Liq. 0.5g/l 60°C, Sirrix 2UDI Liq. 1g/l 20min)Then continue peroxide bleach in the same bath. Addition of Stabilizer® SIFAM 20min)Then continue peroxide bleach in the same bath. Addition of Stabilizer® SIFAM Problem: Tendering of fabric during bleaching Sources & Causes:  The presence of iron on the fabric acts as a decomposition catalyst for H2O2. In a freely circulating bath new sources of iron oxides form, as a chain reaction of homolytic cleavage of H2O2into hydroxide radicals which attacks cellulose to form oxycellulose. Remedies:  Addition of Sirrix® 2UDI Liq. In Peroxide bleach bath or by one step combined protonic pretreatment & scouring. (Sandoclean® PCJ Liq. 0.5g/l 60°C, Sirrix 2UDI Liq. 1g/l Problem: Lower dye-yield & tone changes in some dyed lots Sources & Causes:  Due to improper washing off after pretreatment, residual peroxide will be left over on the fabric. If it is not removed completely, It may lead to the decomposition of some sensitive reactive dyes to non-homogeneous components, in a mixed shade dyeing. Remedies:  To add peroxide Killer . in the neutralisation bath for eliminating H2O2 in a biological way. Bactosol® APN Liq. can be used in winch.  Both the products promote quickly, under optimum conditions, the redox conversion of H2O2To water & oxygen. H2O2To water & oxygen. H2O2To water & oxygen. Problem: Lower dye-yield & tone changes in some dyed lots Sources & Causes:  Due to improper washing off after pretreatment, residual peroxide will be left over on the fabric. If it is not removed completely, It may lead to the decomposition of some sensitive reactive dyes to non-homogeneous components, in a mixed shade dyeing. Remedies:  To add peroxide Killer . in the neutralisation bath for eliminating H2O2 in a biological way. Bactosol® APN Liq. can be used in winch.  Both the products promote quickly, under optimum conditions, the redox conversion of  Both the products promote quickly, under optimum conditions, the redox conversion of Problem: Lower dye-yield & tone changes in some dyed lots Sources & Causes:  Due to improper washing off after pretreatment, residual peroxide will be left over on the fabric. If it is not removed completely, It may lead to the decomposition of some sensitive reactive dyes to non-homogeneous components, in a mixed shade dyeing. Remedies:  To add peroxide Killer . in the neutralisation bath for eliminating H2O2 in a biological way. Bactosol® APN Liq. can be used in winch. Problem: Dark colored patches & Crease Sources & Causes:  Localised swelling of unmercerised cotton.  Drying up of improperly neutralised alkali after mercerising.  Damage of cellulose during the fast transport through the jet nozzle. The damaged portion of the substrate is deeply dyed. (mainly on viscose) Remedies:  Ensure careful feeding of alkali (by linear dosing)  Efficient neutralisation of the alkali using 0.5-1.0% Sirrix®N / YK Liq. before dyeing.  Loading the fabric after setting the bath with Imacol® C2G Liq.alongwith Sandoclean® PCJ Liq.ensuring proper piling & smooth running. Liq.ensuring proper piling & smooth running. Liq.ensuring proper piling & smooth running. Problem: Dark colored patches & Crease Sources & Causes:  Localised swelling of unmercerised cotton.  Drying up of improperly neutralised alkali after mercerising.  Damage of cellulose during the fast transport through the jet nozzle. The damaged portion of the substrate is deeply dyed. (mainly on viscose) Remedies:  Ensure careful feeding of alkali (by linear dosing)  Efficient neutralisation of the alkali using 0.5-1.0% Sirrix®N / YK Liq. before dyeing.  Loading the fabric after setting the bath with Imacol® C2G Liq.alongwith Sandoclean® PCJ  Loading the fabric after setting the bath with Imacol® C2G Liq.alongwith Sandoclean® PCJ Problem: Dark colored patches & Crease Sources & Causes:  Localised swelling of unmercerised cotton.  Drying up of improperly neutralised alkali after mercerising.  Damage of cellulose during the fast transport through the jet nozzle. The damaged portion of the substrate is deeply dyed. (mainly on viscose) Remedies:  Ensure careful feeding of alkali (by linear dosing)  Efficient neutralisation of the alkali using 0.5-1.0% Sirrix®N / YK Liq. before dyeing. 38 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  39. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Problem: Whiteness variation Sources & Causes:  Presence of insoluble earth alkali on some substrate qualities, over stabilises H2O2making the bleaching ineffective. Remedies:  To achieve the optimum consumption of H2O2a protonic pretreatment with Sirrix® 2UDI Liq. Before bleaching is recommended. Liq. Before bleaching is recommended. Liq. Before bleaching is recommended. Problem: Whiteness variation Sources & Causes:  Presence of insoluble earth alkali on some substrate qualities, over stabilises H2O2making the bleaching ineffective. Remedies:  To achieve the optimum consumption of H2O2a protonic pretreatment with Sirrix® 2UDI  To achieve the optimum consumption of H2O2a protonic pretreatment with Sirrix® 2UDI Problem: Whiteness variation Sources & Causes:  Presence of insoluble earth alkali on some substrate qualities, over stabilises H2O2making the bleaching ineffective. Remedies: Problem: Light colored reserved portion on Cotton / Lycra fabrics Sources & Causes:  Improper pretreatment & use of poor quality wetting agents which could not remove the mineral oil-content from the fabric completely. mineral oil-content from the fabric completely. mineral oil-content from the fabric completely. Problem: Light colored reserved portion on Cotton / Lycra fabrics Sources & Causes:  Improper pretreatment & use of poor quality wetting agents which could not remove the  Improper pretreatment & use of poor quality wetting agents which could not remove the Problem: Light colored reserved portion on Cotton / Lycra fabrics Sources & Causes: Remedies:    Remedies: Remedies: After a protonic treatment fabric should be heat set & bleached using Sandoclean® PCJ Liq. As scouring & wetting agent, at pH 10.5. As scouring & wetting agent, at pH 10.5. As scouring & wetting agent, at pH 10.5. After a protonic treatment fabric should be heat set & bleached using Sandoclean® PCJ Liq. After a protonic treatment fabric should be heat set & bleached using Sandoclean® PCJ Liq. 39 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  40. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile OPTICAL BRIGHTENING FAULTS OPTICAL BRIGHTENING FAULTS OPTICAL BRIGHTENING FAULTS Problem: Poor whiteness Sources & Causes:  Some grey cotton carry a lot of hardness forming substances, which interfere in the bleaching reaction of Hydrogen Peroxide on cellulose.  Overdosing of optical whiteners & drying at temperature above 140°C.  Overdosing of optical whiteners & drying at temperature above 140°C.  Overdosing of optical whiteners & drying at temperature above 140°C. Problem: Poor whiteness Sources & Causes:  Some grey cotton carry a lot of hardness forming substances, which interfere in the bleaching reaction of Hydrogen Peroxide on cellulose. bleaching reaction of Hydrogen Peroxide on cellulose. Problem: Poor whiteness Sources & Causes:  Some grey cotton carry a lot of hardness forming substances, which interfere in the Remedies: Remedies: Remedies:    Give a protonic pretreatment before Hydrogen Peroxide bleach using  Sirrix®2UDI / YK Liq.®  Sandoclean®PCJ Liq. Use optimum quantity of optical whitener & controlled drying, preferably below 130°C. Use acid stable OBA in case of neutralizing like Leucophor ®BMF Liq. Use acid stable OBA in case of neutralizing like Leucophor ®BMF Liq. Use acid stable OBA in case of neutralizing like Leucophor ®BMF Liq. Give a protonic pretreatment before Hydrogen Peroxide bleach using  Sirrix®2UDI / YK Liq.®  Sandoclean®PCJ Liq. Use optimum quantity of optical whitener & controlled drying, preferably below 130°C. Use optimum quantity of optical whitener & controlled drying, preferably below 130°C. Give a protonic pretreatment before Hydrogen Peroxide bleach using  Sirrix®2UDI / YK Liq.®  Sandoclean®PCJ Liq.    Problem: Yellowing of whites after Storage Sources & Causes:  BHT ( Butylated Hydroxy Toluene ) is present in polyethylene bags as an anti- oxidant. If the fabric is in the neutral or alkaline side the yellowing reaction starts. the fabric is in the neutral or alkaline side the yellowing reaction starts. the fabric is in the neutral or alkaline side the yellowing reaction starts. Problem: Yellowing of whites after Storage Sources & Causes:  BHT ( Butylated Hydroxy Toluene ) is present in polyethylene bags as an anti- oxidant. If  BHT ( Butylated Hydroxy Toluene ) is present in polyethylene bags as an anti- oxidant. If Problem: Yellowing of whites after Storage Sources & Causes: Remedies:    Remedies: Remedies: Finish the fabric in slightly acidic medium (pH 5.5 - 6.0) using Sirrix® 2UDI Liq., and keep the fabric away from Nitrogen oxides. Use wrapping without BHT. the fabric away from Nitrogen oxides. Use wrapping without BHT. the fabric away from Nitrogen oxides. Use wrapping without BHT. Finish the fabric in slightly acidic medium (pH 5.5 - 6.0) using Sirrix® 2UDI Liq., and keep Finish the fabric in slightly acidic medium (pH 5.5 - 6.0) using Sirrix® 2UDI Liq., and keep 40 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  41. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Problem: Aqueous extract of the fabric is alkaline Sources & Causes:  If Acetic Acid is used for reducing the pH at the end of finishing operation, it forms a buffer of sodium acetate at the liquid- fabric interface and prevents the entry of further Acetic acid to the core of the fibre. to the core of the fibre. to the core of the fibre. Problem: Aqueous extract of the fabric is alkaline Sources & Causes:  If Acetic Acid is used for reducing the pH at the end of finishing operation, it forms a buffer of sodium acetate at the liquid- fabric interface and prevents the entry of further Acetic acid of sodium acetate at the liquid- fabric interface and prevents the entry of further Acetic acid Problem: Aqueous extract of the fabric is alkaline Sources & Causes:  If Acetic Acid is used for reducing the pH at the end of finishing operation, it forms a buffer Remedies:    Remedies: Remedies: Use Sirrix® N for reducing the pH of finish bath which can penetrate into the fibre to neutralise the core alkali, which is responsible for alkaline pH. neutralise the core alkali, which is responsible for alkaline pH. neutralise the core alkali, which is responsible for alkaline pH. Use Sirrix® N for reducing the pH of finish bath which can penetrate into the fibre to Use Sirrix® N for reducing the pH of finish bath which can penetrate into the fibre to Problem: Yellow streaks on white fabrics Sources & Causes:  Poor washing off.  Local drying up marks because of more time gap between hydro extraction and drying. Remedies:  Wash at 85°C to completely remove all impurities & neutralize using Sirrix® N Liq.  Dry the hydro extracted fabrics as early as possible.  Dry the hydro extracted fabrics as early as possible.  Dry the hydro extracted fabrics as early as possible. Problem: Yellow streaks on white fabrics Sources & Causes:  Poor washing off.  Local drying up marks because of more time gap between hydro extraction and drying. Remedies:  Wash at 85°C to completely remove all impurities & neutralize using Sirrix® N Liq.  Wash at 85°C to completely remove all impurities & neutralize using Sirrix® N Liq. Problem: Yellow streaks on white fabrics Sources & Causes:  Poor washing off.  Local drying up marks because of more time gap between hydro extraction and drying. Remedies: Problem: Poor whiteness on Cotton / elastane (lycra) fabrics Sources & Causes:  The basic whiteness of fabric is very low.  Improper selection of optical brightening agent.  Improper selection of optical brightening agent.  Improper selection of optical brightening agent. Problem: Poor whiteness on Cotton / elastane (lycra) fabrics Sources & Causes:  The basic whiteness of fabric is very low.  The basic whiteness of fabric is very low. Problem: Poor whiteness on Cotton / elastane (lycra) fabrics Sources & Causes: Remedies:    Remedies: Remedies: Natural whiteness of lycra can be improved by giving a reductive scour before bleaching.Heat to 75-80°C & run 60 min. Cool the bath to 60°C & drop bath Run 15 min in a fresh bath containing0.3 mg/L H2o2(50%) Rinse cold. fresh bath containing0.3 mg/L H2o2(50%) Rinse cold. fresh bath containing0.3 mg/L H2o2(50%) Rinse cold. Natural whiteness of lycra can be improved by giving a reductive scour before bleaching.Heat to 75-80°C & run 60 min. Cool the bath to 60°C & drop bath Run 15 min in a bleaching.Heat to 75-80°C & run 60 min. Cool the bath to 60°C & drop bath Run 15 min in a Natural whiteness of lycra can be improved by giving a reductive scour before    The selection of optical brightening agent must suit both the lycra & the hard fibre in the fabric. Apply 0.8% in a reducing bath (Soduim Hydrosulphite) at pH of about 5.5. fabric. Apply 0.8% in a reducing bath (Soduim Hydrosulphite) at pH of about 5.5. fabric. Apply 0.8% in a reducing bath (Soduim Hydrosulphite) at pH of about 5.5. The selection of optical brightening agent must suit both the lycra & the hard fibre in the The selection of optical brightening agent must suit both the lycra & the hard fibre in the 41 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  42. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Problem: Loss of whiteness retention of cotton / elastane fabrics Sources & Causes:  Poor working practice and poor storage conditions. Remedies: The following should be avoided:  Unsatisfactory optical whitener. Use only Leucophor® BMF/BH Liq.  Drying with air heated by combustion gas or oil  Unsatisfactory y softener, use Sandolube® HD Liq. and Ceraperm® MW Liq.  Do not store white goods in ex-cessive light (natural / artificial).  Exposure to excessive burnt gas fumes (nitrogen oxides)  Lack of air tight & inert packing.  Packing which releases phenolic derivatives.  Packing which releases phenolic derivatives.  Packing which releases phenolic derivatives. Problem: Loss of whiteness retention of cotton / elastane fabrics Sources & Causes:  Poor working practice and poor storage conditions. Remedies: The following should be avoided:  Unsatisfactory optical whitener. Use only Leucophor® BMF/BH Liq.  Drying with air heated by combustion gas or oil  Unsatisfactory y softener, use Sandolube® HD Liq. and Ceraperm® MW Liq.  Do not store white goods in ex-cessive light (natural / artificial).  Exposure to excessive burnt gas fumes (nitrogen oxides)  Lack of air tight & inert packing.  Lack of air tight & inert packing. Remedies: The following should be avoided:  Unsatisfactory optical whitener. Use only Leucophor® BMF/BH Liq.  Drying with air heated by combustion gas or oil  Unsatisfactory y softener, use Sandolube® HD Liq. and Ceraperm® MW Liq.  Do not store white goods in ex-cessive light (natural / artificial).  Exposure to excessive burnt gas fumes (nitrogen oxides) Problem: Loss of elastic properties in cotton / elastane fibres Sources & Causes:  Improper processing methods.  Improper processing methods.  Improper processing methods. Problem: Loss of elastic properties in cotton / elastane fibres Sources & Causes: Sources & Causes: Problem: Loss of elastic properties in cotton / elastane fibres Remedies: Remedies: Remedies:    Avoid processing of such blends in strongly acidic (pH<4) or strongly alkaline baths (pH>10.5). (pH>10.5). (pH>10.5). Avoid processing of such blends in strongly acidic (pH<4) or strongly alkaline baths Avoid processing of such blends in strongly acidic (pH<4) or strongly alkaline baths    Avoid use of Sodium Hypochlorite Avoid use of Sodium Hypochlorite Avoid use of Sodium Hypochlorite    Excessive steam ageing of printed fabrics. The temperature in cottage steamers should not exceed 104°C (0.2 Kg / cm2 steam pressure) during 30-60 min to maintain the properties of eglantine fibres. properties of eglantine fibres. properties of eglantine fibres. Excessive steam ageing of printed fabrics. The temperature in cottage steamers should not exceed 104°C (0.2 Kg / cm2 steam pressure) during 30-60 min to maintain the not exceed 104°C (0.2 Kg / cm2 steam pressure) during 30-60 min to maintain the Excessive steam ageing of printed fabrics. The temperature in cottage steamers should    High tension and overheating above 150°C should be avoided in finishing. High tension and overheating above 150°C should be avoided in finishing. High tension and overheating above 150°C should be avoided in finishing. 42 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  43. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile FINISHING FAULTS FINISHING FAULTS FINISHING FAULTS Problem: Sewability damage Sources & Causes:  Because of various processing operations, brittleness on the fabric is developed, which does not allow the needle to penetrate the single knit structure smoothly, but pierces, damaging the knit structure. Remedies:  ( Use proper softener for knitted fabrics ) Use of Sandolube® JNF Liq. (for dyed) and Sandolube® HD Liq. (for white) material. Sandolube® HD Liq. (for white) material. Sandolube® HD Liq. (for white) material. Problem: Sewability damage Sources & Causes:  Because of various processing operations, brittleness on the fabric is developed, which does not allow the needle to penetrate the single knit structure smoothly, but pierces, damaging the knit structure. Remedies:  ( Use proper softener for knitted fabrics ) Use of Sandolube® JNF Liq. (for dyed) and  ( Use proper softener for knitted fabrics ) Use of Sandolube® JNF Liq. (for dyed) and Problem: Sewability damage Sources & Causes:  Because of various processing operations, brittleness on the fabric is developed, which does not allow the needle to penetrate the single knit structure smoothly, but pierces, damaging the knit structure. Remedies: Problem: Poor handle of the fabric after cationic dye-fixing & finishing treatment Sources & Causes:  At pH 5.0 to 5.5 most of the cationic softeners exhaust onto cellulose fibres, inde- pendent of temperature. An exception to this rule is the softening of dyed material which Is been treated with dyed cellulosic cationic fixatives.  The fibre has a cationic charge due to fixative. In an acid bath, cationic charge on the fibre and that of softener are activated and repel each other. and that of softener are activated and repel each other. and that of softener are activated and repel each other. Problem: Poor handle of the fabric after cationic dye-fixing & finishing treatment Sources & Causes:  At pH 5.0 to 5.5 most of the cationic softeners exhaust onto cellulose fibres, inde- pendent of temperature. An exception to this rule is the softening of dyed material which Is been treated with dyed cellulosic cationic fixatives.  The fibre has a cationic charge due to fixative. In an acid bath, cationic charge on the fibre  The fibre has a cationic charge due to fixative. In an acid bath, cationic charge on the fibre Problem: Poor handle of the fabric after cationic dye-fixing & finishing treatment Sources & Causes:  At pH 5.0 to 5.5 most of the cationic softeners exhaust onto cellulose fibres, inde- pendent of temperature. An exception to this rule is the softening of dyed material which Is been treated with dyed cellulosic cationic fixatives. Remedies:    Remedies: Remedies: Under such conditions satisfactory exhaustion of the softner can be achieved using Sandolube® JNF Liq. and / or Sandosoft® SPK Liq. at pH 7.0 ] Sandolube® JNF Liq. and / or Sandosoft® SPK Liq. at pH 7.0 ] Sandolube® JNF Liq. and / or Sandosoft® SPK Liq. at pH 7.0 ] Under such conditions satisfactory exhaustion of the softner can be achieved using Under such conditions satisfactory exhaustion of the softner can be achieved using [ [ [ 43 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  44. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Problem: Dark spots on the fabric / Dhappa Sources & Causes:  Using softeners which have poor shear force stability, which forms spots after the emulsion system is disturbed. Remedies:  Softener & dyefixative can be stripped, before redyeing, using 1.0 g/l Lyocol® RDNI Liq. g/l Acetic Acid at 80°C, 30 min, Rinse & Neutralise.  Use of Sandolube® JNF Liq. (Jet stable & non foaming) in finishing.  Use of Sandolube® JNF Liq. (Jet stable & non foaming) in finishing.  Use of Sandolube® JNF Liq. (Jet stable & non foaming) in finishing. Problem: Dark spots on the fabric / Dhappa Sources & Causes:  Using softeners which have poor shear force stability, which forms spots after the emulsion system is disturbed. Remedies:  Softener & dyefixative can be stripped, before redyeing, using 1.0 g/l Lyocol® RDNI Liq. g/l Acetic Acid at 80°C, 30 min, Rinse & Neutralise. g/l Acetic Acid at 80°C, 30 min, Rinse & Neutralise. Problem: Dark spots on the fabric / Dhappa Sources & Causes:  Using softeners which have poor shear force stability, which forms spots after the emulsion system is disturbed. Remedies:  Softener & dyefixative can be stripped, before redyeing, using 1.0 g/l Lyocol® RDNI Liq. Problem: Poor inner softness & elasticity of fabrics (Dyed goods) Problem: Poor inner softness & elasticity of fabrics (Dyed goods) Problem: Poor inner softness & elasticity of fabrics (Dyed goods) Sources & Causes:    Sources & Causes: Sources & Causes: Many of the commercial aminosilicones have particle size above 0.1 Micron which cannot penetrate into the core of the fibre to provide an excellent product distribution to give inner softness without looking greasy. Remedies:  Use Sandoperm® MEJ Liq. By exhaust method or Ceraperm® MW Liq. by padding method. (for whites & dyed fabrics)  Both the above products increase technological properties (mainly supports elasticity), apart from increasing the softness apart from increasing the softness apart from increasing the softness Many of the commercial aminosilicones have particle size above 0.1 Micron which cannot penetrate into the core of the fibre to provide an excellent product distribution to give inner softness without looking greasy. Remedies:  Use Sandoperm® MEJ Liq. By exhaust method or Ceraperm® MW Liq. by padding method. (for whites & dyed fabrics)  Both the above products increase technological properties (mainly supports elasticity),  Both the above products increase technological properties (mainly supports elasticity), Many of the commercial aminosilicones have particle size above 0.1 Micron which cannot penetrate into the core of the fibre to provide an excellent product distribution to give inner softness without looking greasy. Remedies:  Use Sandoperm® MEJ Liq. By exhaust method or Ceraperm® MW Liq. by padding method. (for whites & dyed fabrics) Problem: Poor hydrophilicity of fabrics Sources & Causes:  Improper softener selection. Cotton fibre is hydrophilic. It becomes hydrophobic because of the oriented adsorption of cationic softener. Remedies:  Use Dilasot® RWS Liq. & Sandolube® HD Liq. in exhaust and Sandolube® HD Liq. in padding. padding. padding. Problem: Poor hydrophilicity of fabrics Sources & Causes:  Improper softener selection. Cotton fibre is hydrophilic. It becomes hydrophobic because of the oriented adsorption of cationic softener. Remedies:  Use Dilasot® RWS Liq. & Sandolube® HD Liq. in exhaust and Sandolube® HD Liq. in  Use Dilasot® RWS Liq. & Sandolube® HD Liq. in exhaust and Sandolube® HD Liq. in Problem: Poor hydrophilicity of fabrics Sources & Causes:  Improper softener selection. Cotton fibre is hydrophilic. It becomes hydrophobic because of the oriented adsorption of cationic softener. Remedies: Problem: Poor feel on white fabrics Sources & Causes:  If softener is applied by exhaust method, it is difficult to exhaust the softener since only non-ionic softeners / anionic / amphoteric are recommended for white goods. Remedies:  Use Ceranine® RSFLF Liq. At pH-5.0. Use acid stable OBA likeLeucophor® BMF Liq.  Pad with Ceraperm® MW Liq. & Ceraperm® MN or UP Liq.  Use yellow softener for white fabrics  Dryeing in the stenter at lower temperature .  Dryeing in the stenter at lower temperature .  Dryeing in the stenter at lower temperature . Problem: Poor feel on white fabrics Sources & Causes:  If softener is applied by exhaust method, it is difficult to exhaust the softener since only non-ionic softeners / anionic / amphoteric are recommended for white goods. Remedies:  Use Ceranine® RSFLF Liq. At pH-5.0. Use acid stable OBA likeLeucophor® BMF Liq.  Pad with Ceraperm® MW Liq. & Ceraperm® MN or UP Liq.  Use yellow softener for white fabrics  Use yellow softener for white fabrics Problem: Poor feel on white fabrics Sources & Causes:  If softener is applied by exhaust method, it is difficult to exhaust the softener since only non-ionic softeners / anionic / amphoteric are recommended for white goods. Remedies:  Use Ceranine® RSFLF Liq. At pH-5.0. Use acid stable OBA likeLeucophor® BMF Liq.  Pad with Ceraperm® MW Liq. & Ceraperm® MN or UP Liq. Problem: Dark colored oil spots Problem: Dark colored oil spots Problem: Dark colored oil spots 44 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  45. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Sources & Causes:    Sources & Causes: Sources & Causes: Often encountered when the goods are given silicone finishing agent treatment in soft flow machine using SILICONES which are NOT jet stable. Remedies:  Use jet-stable silicones.  Use jet-stable silicones.  Use jet-stable silicones. Often encountered when the goods are given silicone finishing agent treatment in soft flow machine using SILICONES which are NOT jet stable. Remedies: Remedies: Often encountered when the goods are given silicone finishing agent treatment in soft flow machine using SILICONES which are NOT jet stable. Problem: Pin hole seen in a straight line at regular repeat intervals Sources & Causes:  Presence of embedded metal object in the finishing line. Remedies:  Check for any sharp objects.  Check for any sharp objects.  Check for any sharp objects. Problem: Pin hole seen in a straight line at regular repeat intervals Sources & Causes:  Presence of embedded metal object in the finishing line. Remedies: Remedies: Problem: Pin hole seen in a straight line at regular repeat intervals Sources & Causes:  Presence of embedded metal object in the finishing line. Problem: Damage of viscose fabrics after dyeing Sources & Causes:  Residual caustic left in viscose & its blends after reactive dyeing can degrade the viscose when heated. Remedies:  Core alkali should be removed using Sirrix® N Liq. or Sirrix® 2UDI Liq. & Acetic acid mixture 50:50. mixture 50:50. mixture 50:50. Problem: Damage of viscose fabrics after dyeing Sources & Causes:  Residual caustic left in viscose & its blends after reactive dyeing can degrade the viscose when heated. Remedies:  Core alkali should be removed using Sirrix® N Liq. or Sirrix® 2UDI Liq. & Acetic acid  Core alkali should be removed using Sirrix® N Liq. or Sirrix® 2UDI Liq. & Acetic acid Problem: Damage of viscose fabrics after dyeing Sources & Causes:  Residual caustic left in viscose & its blends after reactive dyeing can degrade the viscose when heated. Remedies: Problem: Silicone stains on fabrics even after using Jet stable silicone Sources & Causes:  Due to direct heating of the bath / silicone. silicone. silicone. Problem: Silicone stains on fabrics even after using Jet stable silicone Sources & Causes:  Due to direct heating of the bath /  Due to direct heating of the bath / Problem: Silicone stains on fabrics even after using Jet stable silicone Sources & Causes: Remedies:    Remedies: Remedies: The fabric to be finished should not have anionic residues; silicone can be added to hot bath at 50°C but never heat after adding softener. heat after adding softener. heat after adding softener. The fabric to be finished should not have anionic residues; silicone can be added to hot bath at 50°C but never added to hot bath at 50°C but never The fabric to be finished should not have anionic residues; silicone can be Problem: Oil stains near the edge of tubes & also on the body randomly (Mainly on Navy & Black Shades) Sources & Causes: Sources & Causes: Sources & Causes: Problem: Oil stains near the edge of tubes & also on the body randomly (Mainly on Navy & Black Shades) Black Shades) Problem: Oil stains near the edge of tubes & also on the body randomly (Mainly on Navy & 45 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  46. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile    Maintenance of pH not only in the bath but also on the fabric is important, otherwise rubbery film formed in finish bath will adhere to the fabric & forms silicone stains, which appears after drying. Remedies:  Use Stripper® SS for removing silicone stains.  Navy shades can be produced using Drimarene® XN Liq. Instead of vinyl sulphone dyes.  Efficient removal of core alkali using Sirrix® 2UDI Liq.  Efficient removal of core alkali using Sirrix® 2UDI Liq.  Efficient removal of core alkali using Sirrix® 2UDI Liq. Maintenance of pH not only in the bath but also on the fabric is important, otherwise rubbery film formed in finish bath will adhere to the fabric & forms silicone stains, which appears after drying. Remedies:  Use Stripper® SS for removing silicone stains.  Navy shades can be produced using Drimarene® XN Liq. Instead of vinyl sulphone dyes.  Navy shades can be produced using Drimarene® XN Liq. Instead of vinyl sulphone dyes. Maintenance of pH not only in the bath but also on the fabric is important, otherwise rubbery film formed in finish bath will adhere to the fabric & forms silicone stains, which appears after drying. Remedies:  Use Stripper® SS for removing silicone stains. Problem: Ballooning shape. Sources & Causes: • Feed the twist fabric in the squeezer m/c. • Roller pressure variation. • Over pick variation. • RPM variation. Remedies: • With carefully, fabric feeding in the squeezer m/c. • Proper roller pressure & RPM are feed. • Right the over pick feed. • Right the over pick feed. • Right the over pick feed. Problem: Ballooning shape. Sources & Causes: • Feed the twist fabric in the squeezer m/c. • Roller pressure variation. • Over pick variation. • RPM variation. Remedies: • With carefully, fabric feeding in the squeezer m/c. • Proper roller pressure & RPM are feed. • Proper roller pressure & RPM are feed. Problem: Ballooning shape. Sources & Causes: • Feed the twist fabric in the squeezer m/c. • Roller pressure variation. • Over pick variation. • RPM variation. Remedies: • With carefully, fabric feeding in the squeezer m/c. Problem: Radish shade. Sources & Causes: • Increase temperature in dryer. • Increase the gas pressure. • Decay the trum plate. • Improper roller RPM. Remedies: • Proper the temperature in dryer. • Improve the trum-plate. • Proper the gas pressure. • Proper roller RPM on the temperature. • Proper roller RPM on the temperature. • Proper roller RPM on the temperature. Problem: Radish shade. Sources & Causes: • Increase temperature in dryer. • Increase the gas pressure. • Decay the trum plate. • Improper roller RPM. Remedies: • Proper the temperature in dryer. • Improve the trum-plate. • Proper the gas pressure. • Proper the gas pressure. Problem: Radish shade. Sources & Causes: • Increase temperature in dryer. • Increase the gas pressure. • Decay the trum plate. • Improper roller RPM. Remedies: • Proper the temperature in dryer. • Improve the trum-plate. 46 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  47. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Problem: Squeezer mark. Sources & Causes: • Improper roller pressure. • RPM variation. • Improper over pick. Remedies: • Proper roller pressure. • Right the RPM to fixed in the m/c. • Proper over pick. • Proper over pick. Problem: Squeezer mark. Sources & Causes: • Improper roller pressure. • RPM variation. • Improper over pick. Remedies: • Proper roller pressure. • Right the RPM to fixed in the m/c. Problem: Dia mark. Sources & Causes: • Improper Dia leg. • Press the leg guide/wheel. • To decay the leg guide/circle. Remedies: • Proper Dia leg feed in the m/c. • Repairing the Dia leg wheel. • Proper press the Dia leg circle. • Proper press the Dia leg circle. Problem: Dia mark. Sources & Causes: • Improper Dia leg. • Press the leg guide/wheel. • To decay the leg guide/circle. Remedies: • Proper Dia leg feed in the m/c. • Repairing the Dia leg wheel. Problem: Dirty spot. Sources & Causes: • To stay dirty in the floor. • Uncarefully labour. • To stay dirty in the m/c. • To stay dirty in the m/c. Problem: Dirty spot. Sources & Causes: • To stay dirty in the floor. • Uncarefully labour. Remedies: Remedies: • Clean the floor at everyday. • Carefully labour. • To clean the m/c per week. • To clean the m/c per week. • Clean the floor at everyday. • Carefully labour. 47 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  48. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Problem: Compaction /Press mark. Sources & Causes: • Compacting roller pressure uneven. • Improper roller. • Improper RPM. • Over pick variation. • Steam pressure variation. Remedies: • Even compacting roller pressure. • Proper roller. • Will be give the right over pick. • Proper steam pressure & RPM. • Proper steam pressure & RPM. Problem: Compaction /Press mark. Sources & Causes: • Compacting roller pressure uneven. • Improper roller. • Improper RPM. • Over pick variation. • Steam pressure variation. Remedies: • Even compacting roller pressure. • Proper roller. • Will be give the right over pick. Problem: Compacting hole. Sources & Causes: • More steam pressure. • Low roller RPM . • Uneven roller. Remedies: • Proper steam pressure. • Proper roller RPM. • Feeding the even roller in compacting m/c. m/c. Problem: Compacting hole. Sources & Causes: • More steam pressure. • Low roller RPM . • Uneven roller. Remedies: • Proper steam pressure. • Proper roller RPM. • Feeding the even roller in compacting Problem: Calendaring crease. Sources & Causes: • Improper calendar roller pressure. • Fabric Tension variation. • More lacra use of knit fabric. Remedies: • Proper calendar roller pressure. • Right the fabric tension. • Less lacra use. • More softener use. • More softener use. Problem: Calendaring crease. Sources & Causes: • Improper calendar roller pressure. • Fabric Tension variation. • More lacra use of knit fabric. Remedies: • Proper calendar roller pressure. • Right the fabric tension. • Less lacra use. 48 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  49. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile Problem: Oil Spot Sources & Causes: Sources & Causes: Problem: Oil Spot • More oil & grease use the wheel, roller bearing intoplace. • To stay unclean the m/c. • Be decay the roller. • Fabric waste. Remedies: • Proper oil & grease use in place of the wheel, Bearing in roller. • To stay clean the m/c at week. • Repairing the roller. • Repairing the roller. • More oil & grease use the wheel, roller bearing intoplace. • To stay unclean the m/c. • Be decay the roller. • Fabric waste. Remedies: • Proper oil & grease use in place of the wheel, Bearing in roller. • To stay clean the m/c at week. Problem: Improper shrinkage. Sources & Causes: • Heavy roller pressure. • Not over pick in finishing m/c. • Temperature variation. • RPM variation. • Under pick causes. Remedies: • Proper roller pressure. • Must be over pick. • Proper Temperature. Right the RPM fixed. • Right the RPM fixed. Problem: Improper shrinkage. Sources & Causes: • Heavy roller pressure. • Not over pick in finishing m/c. • Temperature variation. • RPM variation. • Under pick causes. Remedies: • Proper roller pressure. • Must be over pick. • Proper Temperature. • 49 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

  50. Southeast University Department of Textile Southeast University Department of Textile Southeast University Department of Textile DYEING FAULT DYEING FAULT DYEING FAULT Problem: Reduction in dye yield Sources & Causes:  Presence of residual peroxide decomposes some sensitive reactive dyes, the effect of which is very predominant in pastel shades.  Reduction of Drimarene XN dyestuff caused by the reducing atmosphere created because of the reducing substances present in water (when dyeing temperature is 85 - 95°C). of the reducing substances present in water (when dyeing temperature is 85 - 95°C). of the reducing substances present in water (when dyeing temperature is 85 - 95°C). Problem: Reduction in dye yield Sources & Causes:  Presence of residual peroxide decomposes some sensitive reactive dyes, the effect of which is very predominant in pastel shades.  Reduction of Drimarene XN dyestuff caused by the reducing atmosphere created because  Reduction of Drimarene XN dyestuff caused by the reducing atmosphere created because Problem: Reduction in dye yield Sources & Causes:  Presence of residual peroxide decomposes some sensitive reactive dyes, the effect of which is very predominant in pastel shades. Remedy:    Remedy: Remedy: Use Clariant’s PROTOBLEACH concept using Sirrix® PK Liq. or Bactosol® ARLI Liq. for clearing residual H2O2. Use Revatol® S pdr. 1 -2 g/l while dyeing cotton / viscose using Drimarene® XN dyes. Use Revatol® S pdr. 1 -2 g/l while dyeing cotton / viscose using Drimarene® XN dyes. Use Revatol® S pdr. 1 -2 g/l while dyeing cotton / viscose using Drimarene® XN dyes. Use Clariant’s PROTOBLEACH concept using Sirrix® PK Liq. or Bactosol® ARLI Liq. for clearing residual H2O2. clearing residual H2O2. Use Clariant’s PROTOBLEACH concept using Sirrix® PK Liq. or Bactosol® ARLI Liq. for    Problem: Dimpling (or cockling) of fabric surface Sources & Causes:  Running heat sensitive (or thermo plastic) fabrics at too low speed during cooling. Remedy:  Increase the liquor ratio and arrive at a “compromise speed”.  Increase the liquor ratio and arrive at a “compromise speed”.  Increase the liquor ratio and arrive at a “compromise speed”. Problem: Dimpling (or cockling) of fabric surface Sources & Causes:  Running heat sensitive (or thermo plastic) fabrics at too low speed during cooling. Remedy: Remedy: Problem: Dimpling (or cockling) of fabric surface Sources & Causes:  Running heat sensitive (or thermo plastic) fabrics at too low speed during cooling. Problem: Pilling of fabrics Sources & Causes:  Because of salt and alkali addition in the dyebath, the specific gravity of the bath increases. Hence, even fabric surface to surface contact at high speed generates pilling due to heavy friction. friction. friction. Problem: Pilling of fabrics Sources & Causes:  Because of salt and alkali addition in the dyebath, the specific gravity of the bath increases. Hence, even fabric surface to surface contact at high speed generates pilling due to heavy Hence, even fabric surface to surface contact at high speed generates pilling due to heavy Problem: Pilling of fabrics Sources & Causes:  Because of salt and alkali addition in the dyebath, the specific gravity of the bath increases. Remedy:    Remedy: Remedy: Use 0.5 - 1.0 g/l Imacol® C2G Liq. in dye bath. Use 0.5 - 1.0 g/l Imacol® C2G Liq. in dye bath. Use 0.5 - 1.0 g/l Imacol® C2G Liq. in dye bath. 50 Industry : Knit Concern Group Industry : Knit Concern Group Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies | Project : Knit Dyeing Faults and Remedies

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