Dyeing faults and their remedies
Textile Apex (http://www.textileapex.blogspot.com)
Uneven dyeing
Causes
Due to improper pretreatment.
Very rapid addition of dyes and chemicals.
Lack of controlling dyeing parameters
Remedies
Check addition of dyes and chemicals are at a steadily increasing rate.
Proper pretreatments.
Check the rope turnover time.
Proper washing after dyeing.
Running shade
Causes
Machine loading is higher.
Running at lower nozzle pressure.
High bath draining temperature.
Remedies
Proper cycle time should be ensured.
Nozzle pressure should be accurate.
Bath draining temperature should be moderate.
Crease mark
Causes
Excessive loading of fabric during dyeing.
Sudden change in temperature during cooling.
Due to lack of synchronization of winch speed and pump pressure.
Remedies
Follow the temperature gradation during the whole cycle of dyeing.
Fabric must be loaded according to loop length.
Maintaining the proper synchronization between the winch speed and pump
pressure.
Pin hole
Causes
Due to presence of traces of Fe+ and Cu+ ions in the process bath.
If soda dosing is done at high temperature then in presence of oxygen pin
hole is created.
Inadequate amount of stabilizer im H2O2 bleaching.
Remedies
The water used in dyeing should be free from water hardness.
Soda dosing should be done at low temperature (not more than 600C)
Dye spot
Causes
Improper mixing and dissolving of dyestuff.
Dye bath hardness.
Remedies
Mixing and dosing of dyestuffs should be done properly.
Water of dye bath should hardness free.
Soda spot
Causes
If soaping start before wash
CaCO3 or MgCO3 in soaping bath
Quick soda dosing
Remedies
Soda particles should be dissolved properly.
After pre-treatment and dyeing, proper neutralization should be done.
Fly dye stains
Causes
If dye is mixed in the dyeing floor then flying dust particles may come in
contact with the dissolved dyestuffs.
If dyeing floor is too dirty.
Remedies
Dyes should be dissolved in separate drum and in separate room.
Dyeing floor must be neat and clean.
Trims shade not match with the body
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.
Remedies
Same type of yarn, dye lot, recipe, nozzle pressure ,uniform distribution to
each nozzle etc. should be used for both fabric and trims.
Softener Marks
Causes
If pH is not maintained
Poor emulsification of softener applied
Inferior quality of softener
Remedies
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.
Barrie
Causes
High yarn tension
Count variation
Mixing of the yarn lots
Remedies
Ensure uniform yarn tension to all the feeders.
Ensure that the yarn being used for knitting is from the same lot.
Metamerism
Causes
This is because, dye class is not same for all ropes in a batch or when
collar/cuff is dyed using dyes from one lot and body fabric is dyed using
dyes from different lot.
Remedies
To overcome this, one has to choose same dye class which will give same
shade at least under primary and secondary light source.
Hand feel problem
Causes
Use of harsh metal chemicals for processing.
Insufficient softeners application in dyeing machine.
Remedies
It can be easily reduced by demineralization and can be improved by the
addition of softener.
