IDENTIFICATION OF DIFFERENT TYPES OF DYEING FAULT

e-ISSN: 2582-5208 International Research Journal of Modernization in Engineering Technology and Science

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IDENTIFICATION OF DIFFERENT TYPES OF DYEING FAULT, CAUSES AND

CONTROLLING METHOD FOR QUALITY AND PRODUCTIVITY

IMPROVEMENT

Md. Mazharul Islam*1

*1Student, Department of Textile Engineering, Primeasia University, Dhaka, Bangladesh.

ABSTRACT Bangladesh is earning about 80% foreign currency from the textile sector by exporting the textile products

mainly to European region and USA. Nowadays this field has become very competitive. Quality of product is

very important to everyone. Buyers are very aware about the quality of product. To get quality product the

faults, which are occurring in different stages such as dyeing, printing and finishing, should be minimal. Due to

the faults, the production hampers and quality of the product degrades. Quality is the demands and when it

fulfils then it gives customer satisfaction and also enhances standard of a product. Whether the fault and quality

is maintained, also improve productivity. The goal of this research is to identify the dyeing faults for quality and

productivity improvement by controlling imperfection.

Keywords: Garments Washing, Garments Dyeing, Knit fabrics, Woven fabric, Dyeing faults, Causes and

Remedies, Quality Control, Productivity, Production, Cost Reduction.

I. INTRODUCTION

Dyeing is a process of treating fabric with dye liquors, which contain both dyestuffs & chemicals and fixing the

dyes subsequently on the fabric. During dyeing process, a lot of faulty dyed fabrics come out. Faults may arise

because of the followings

• Wrong pre-treatment procedures

• Insufficient agitation of dyeing liquor

• Wrong placement of fabric into the machine

• Improper working of dyeing machines

• Applying unsuitable dyeing recipes

• Pressure differences along the length of the squeeze rollers etc.

As dyeing faults incur losses we need to be conscious to produce fault free products hence facilitating cost

effective production.

II. EXPERIMENTAL 2.1 Methodology

Figure 1

2.2 Procedure

❖ First we have selected different textile industries & visited Dyeing sections (woven & knit),

❖ Then we have collected faulty dyed fabric samples.

❖ To confirm the proper causes & their remedies we have interviewed the related person and collected

information.

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2.3 Poor Leveling or Uneven Dyeing

Figure 2

Probable Causes:

❖ Poor dye solubility

❖ Low dye diffusion

❖ High dye affinity

❖ Dyes poor migration

❖ Too much salt

❖ Rate of dyeing to high

❖ Rapid rate of rise of temperature

Recommended Solution:

❖ Use of dyes of good solubility

❖ Use of dyes of optimum affinity

❖ Use of dyes of good migration

❖ Optimum concentration of salt

❖ Optimum rate of dyeing

❖ Optimum rate of rise of temperature

2.4 Dye specks or sport

Figure 3

Probable Causes:

❖ Poor pretreatment

❖ Water contamination

❖ Contaminants in salt, alkali, etc.

❖ Insufficient dissolving of the dyestuff

❖ The flying about dye particles which cling on to fabric

❖ Improper cleaning of the dyeing machine after color change


❖ Good pretreatment

❖ Water purification or use of sequesting agent

❖ Good quality control of commodity chemicals

❖ Usually it is possible to remove these spots by hot wash with soaping agent





2.5 Crease Mark

Figure 4

Probable Causes:

❖ Over loading of the dyeing machine

❖ Dyeing at high temperature

❖ On synthetic fabrics it occurs because of the contraction caused by hot air and/hot water

❖ In dye bath, anti-creasing agent is not work perfectly


❖ Can be removed from cotton goods by treating with crack inhibitors/cross-linking agent

❖ In mercerizing process

❖ Thermos fixation needed for synthetics

❖ Anti-creasing agent work with perfectly

2.6 Oil & Grease Spot

Figure 5

Probable Causes:

❖ During dyeing & finishing process sometimes oil & grease may fall on fabric which may cause oil &

grease spot on the dye fabric

❖ Due to careless transport of dyed or finished fabric


❖ Must be careful about oil & grease during dyeing & finishing process

❖ Must be careful about the transportation of dyed or finished fabric

2.7 Needle hole

Figure 6





Probable Causes:

❖ If yarn strength is less

❖ If needle is curve

❖ If mineral metal stay in fiber

❖ If broken needle is active on needle action


❖ Sufficient yarn strength is necessary

❖ Proper pre-treatment is required

❖ Before starting needle action, needle should be checked

2.8 Piling

Figure 7

Probable Causes:

❖ Susceptible fiber origin (also in fiber blends)

❖ Inconsistence dimensional stability due to shrinkage


❖ Select fibers carefully

❖ Use selected softeners

2.9 Unlevel

Figure 8

Probable Causes:

❖ Wrong placement of the fabric in machine

❖ Improper working of dyeing apparatus

❖ Applying unsuitable dyeing recipes


❖ This type of faults can be dominated by either removing the dye or re-dyeing or re-wash the fabric into

dark shades like black or navy.

2.10 Physical Damage

Figure 9





Probable Causes:

❖ Too long dyeing time

❖ Too high mechanical or hydraulic action

❖ Too high temperature

❖ High Drum RPM


❖ Right first time dyeing

❖ Optimum hydraulic or mechanical action

❖ Optimum temperature

2.11 Water Spot

Figure 10

Probable Causes:

❖ Fixation with a few drops of water on specific are of dyed fabric


❖ Need Proper fixation

2.12 Hairiness

Figure 11

Probable Causes:

❖ Carded yarn produces highly hairiness fabric

❖ Improper singeing


❖ Use combed yarn

❖ Proper singeing

2.13 White Spot

Figure 12

Probable Causes:

❖ Due to dead fiber






❖ Remove dead fiber during spinning

2.14 Shading

Figure 13

Probable Causes:

❖ Fabric shade variation is the variation of shade or depth of color in same fabric roll.


❖ Numbering of each single parts of garments should be accurate.

❖ Operator must check the garments number before sewing.

2.15 Trims shade not match with the body

Figure 14

Probable Causes:

❖ Different types of yarns used in fabric and trims.

❖ Dye lot is different for trims and body.

❖ Improper recipe setting for trims and fabric.


❖ Same type of yarn, dye lot, recipe, nozzle pressure, uniform distribution to each nozzle etc.

❖ Should be used for both fabric and trims.

2.16 Running shade problem

Figure 15

Probable Causes:

❖ Machine loading is higher.

❖ Running at lower nozzle pressure.

❖ High bath draining temperature.






❖ Proper cycle time should be ensured.

❖ Nozzle pressure should be accurate.

❖ Bath draining temperature should be moderate.

2.17 Softener Mark

Probable Causes:

❖ If pH is not maintained

❖ Poor emulsification of softener applied

❖ Inferior quality of softener


❖ Ensure that the softener is uniformly dissolved in the water

❖ Use the right softener and the correct procedure for the application.

❖ Maintain the correct ph.

2.18 Lycra Breakage

Figure 16

Probable Causes:

❖ During dry process getting stress out

❖ Use inappropriate size of silicon carbide paper for hand scraping

❖ Use improper ratio of chemical

❖ Temperature and wash time not control exactly

❖ When don’t wash by lycra protector


❖ Before Wash garments/fabric treated by lycra protector

❖ During dyeing use lubricating agent

❖ During garments wash reduce machine RPM

❖ Properly Maintain wash time and chemical

III. SURVEY RESULT & ANALYSIS

Our survey time one month here, we show the Average survey result of three sectors (Garments Washing, Knit

Dyeing and Woven Dyeing)

Average Survey Result of Garments Washing per day:

Table 1

Defects Name Total Defect Per Day Defect %

shade light 126 1.13

shade dark 110 0.98

shade blue 75 0.7

Tin /Color More 23 0.21





wash crease mark 16 0.14

wash uneven 12 0.11

line mark 5 0.04

color spot 12 0.11

Dirty spot 37 0.33

Bleach Spot 9 0.08

Oil Spot 5 0.04

Part shading 4 0.04

Total Defects 432

Total No. of Pieces

Inspected

11183

Defect Hundred per

unit (DHU)

3.86%

Figure 17

After 30 days survey we got average result per day 3.8%. We see in washing sector shading issue is a main

problem but sometimes during garments dyeing we facing lots of problem like uneven, crease mark, color spot

arise. That’s why when any problem arise we follow recommendation suggestion and try to minimize those

issue.

Average Survey Result of Woven Dyeing per day:

Table 2

Defects Name Total Dyeing Fault

Per Day

Fault %

Color Spot 3 0.4

Running shade 4 0.5

Uneven Shade 2 0.3

Crease mark 2 0.3

Stop mark 1 0.1

White spot 1 0.1

Oil Spot 2 0.3

Washing Defect

shade light shade dark shade blue Tin /Color More

wash crease mark wash uneven line mark color spot

Dirty spot Bleach Spot Oil Spot Part shading





Oil mark 2 0.3

Line mark 3 0.4

Water spot 1 0.1

Total Dyeing

Fault

20

Total Fabric

Inspected

750 Meter

Total Dyeing

Fault %

2.67%

Figure 18

After 30 days survey we got average result per day Woven Dyeing Fault 2.67%. If we see the chart, we see that

running shade are most commonly problem in woven dyeing. Color spot and uneven dyeing are also found in

good percentage. White spot & Water Spot are less founded fault in woven dyeing. When any dyeing problem

arise, we follow the recommendation suggestion for solving this problem and reduce Dyeing Fault.

Average Survey Result of Knit Dyeing per day:

Table 3

Defects Name Total Dyeing Fault

Per Day

Fault %

Dyeing spot 3 0.6

Soda spot 2 0.4

Uneven dyeing 3 0.6

Running shade 1 0.2

Chemical spot 2 0.4

Wrinkle mark 1 0.2

unwanted mark 2 0.4

Oil mark 1 0.2

14%

18%

11%

11%3%

3%

11%

11%

14%4%

Dyeing Fault of Woven Fabric

Color Spot Running shade Uneven Shade Crease mark Stop mark

White spot Oil Spot Oil mark Line mark Water spot





Softener mark 1 0.2

Shrinkage 0.5 0.1

Total Dyeing Fault 16.5

Total Fabric

Inspected

500 kg

Total Dyeing Fault

%

3.30%

Figure 19

After 30 days survey we got average result per day Knit Dyeing Fault 3.30 %. From the pie chart, we shows that

the most commonly found dyeing spot, chemical spot. Shrinkage are less founded fault in knit dyeing. When any

dyeing problem arise, we follow the recommendation suggestion for solving this problem and reduce Dyeing

Fault.

IV. CONCLUSION

In this research work, we have acquired the ideas, principles & procedures involved with the dyeing faults,

their causes & remedies. For getting optimum production with desired quality, one should be aware of the

faults, which are occurring in different manufacturing stages. From this research work, we got different survey

result among Washing, Woven dyeing and knit dyeing. We hope our work will help to reduce fault and produce

quality product in this competitive market. This paper helped us to be conscious about the dyeing faults and to

take remedial actions accordingly.

V. REFERENCE [1] P. S. Chinta and S. Dhar, Problems in Dyeing and Their Remedies, Research Gate, 2007.

[2] E. FEILMANN, Some Unsolved Dyeing Problems, Journal of the Society of Dyers and Colorists, 2008.

[3] Moin, C.J., and Mahabubuzzaman, A.K.M. 2009. Process for level dyeing of 100% cotton knit fabrics with

reactive dye. J. in-nov.dev. strategy 3(4): 01 08.

[4] Md. Moyinul Islam, Sakil Mahmud. Study on Different Types of Dyeing Faults, Causes and Remedies of Knit

Fabrics. IJET-IJENS Vol:15 No:02.

[5] Mohammad Abu Taher , Md. Mostafizur Rahman. Study on Different Types of Knitting Faults, Causes and

Remedies of Knit Fabric. SAP 2016, 5(6):119-131.

[6] http://web.b.ebscohost.com/abstract?direct=true&profile=ehost&scope=site&authtype=crawler&jrnl=13

003356&AN=74425718&h=niDowfP1lajbLOLo6PMbIUDDVsdojADLFnHRa9kHf7omC23uPpRBxn2vjFhRZ

19%

12%

18%6%

12%

6%

12%6%6%3%

Dyeing Fault of Knit Fabric

Dyeing spot Soda spot Uneven dyeing Running shade

Chemical spot Wrinkle mark unwanted mark Oil mark

Softener mark Shrinkage


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wler%26jrnl%3d13003356%26AN%3d74425718.

[7] http://www.garmentexporthouse.com/2013/12/what-is-shade-variation-in-fabrics.html.

[8] http://garmentspedia.blogspot.com/2015/11/garments-defects-stitching-in-garments.html.

Industries

[9] Norp Knit Industries Ltd. Gazipur, Bangladesh.

[10] NZ Textile Ltd. Dhaka, Bangladesh.

[11] Consumer Knitex Ltd. Mymensingh, Bangladesh.





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IDENTIFICATION OF DIFFERENT TYPES OF DYEING FAULT