48172926 dyeing and printing defects
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Dyeing And Printing
DefectsAnalysis
Submitted by:-
Yash Vyas
A.P-V
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Classification Of Defects
Minor Defect
A defect is defined as minor
defect that is not likely to reduce the
usability of the product, but neverthelessmay negatively influence the sales.
The minor defects can be untrimmed
thread-ends, slight dirt in a non-noticeablezone which can be removed, etc.
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Classification Of Defects
Major Defect:
A defect that, if conspicuous on the
finished product, would cause the item to
be a second. (A "second" is a garment with
a conspicuous defect that affects the
salability or serviceability of the item.
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Dyeing Defects
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Causes Of Dyeing Defects
Due to Material:
Material having dead fibers or other defective fibers.
Left over of Chemicals after bleaching etc.
Material not properly desized.
Material not properly mercerized.
Absorbency of the fabric not proper.
Sticking of insoluble material on the fibers.
Impurities are not removed properly.
Uneven heat treatment.
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Causes Of Dyeing Defects
Due to Water Quality:
More Hardness of water
Water has metal ions such as iron.
pH of water not proper
Water having more chlorine
Due to Improper Dye Solution:
Improper weight ratio of colors, material and chemicals.
Improper material to water ratio
Improper filtering of concentrated colors.
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Barre
Its horizontal shaded
band across the width of
the fabric.
It may be caused by
variation in the size of the
filling yarn and by thedifferences in tension of
either the filling or warp
yarns.
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Bleeding
Its a loss of color when the dyedfabric is wetted or emerged inwater.
The water here, becomes coloredand may cause discoloration ofother fabrics.
This is usually due to eitherimproper dye selection or poordye fastness.
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Shade Bar
It is a horizontal band of
a different hue running
across the fabric.
It may be caused by a
change of filling bobbin
in the loom or a loom
stop and start up
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Shading
It is a variation in color
tone either
horizontally or
vertically.
It is generally due to
uneven tension on the
fabric.
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Stained
It indicates a
discoloration caused
by a foreign substance,dirt, grease, oil or
sizing residue on the
fabric being dyed.
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Hole in sulfur
dyed fabric
Caused due to tendering which
takes place because sulphur is
converted into sulphuric acid
after oxidation which is harmful
for the cellulosic fibers.
This is a major defect. The defect
occurred after washing the
garment.
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Printing Defects
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Methods of Printing
1. Block
2. Stencil
3. Screen
4. Flat Press
5. Roller
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Flushing/Wicking
Caused due to Low viscosity of
print paste.
It occurs when the printed area
bleeds out into the unprinted
area. The result is a shadowing
effect around the outline of the
pattern design.
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Bleeding
Caused due to Low viscosity of
print paste
It is major defect as it happens
throughout the fabric unless
the viscosity is corrected.
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Misfits
A misfit is a print defect caused by improper alignment of the
screens. Also known as out of registration, misfits leave
unprinted areas in the design.
For example, a green leaf may overlap its black outline or
print over another color.
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Stick-ins
A stick-in occurs when a small fiber or piece of lint gets stuck
in the screen opening.
The result is a small unprinted circle in the design. A stick-in is
very difficult to see and often goes unnoticed during a long
run.
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Scrimps
A scrimp defect occurs when the fabric creases underneath
one of the screens during the printing process.
The pattern is then printed on top of the crease, leaving a
large unprinted area when the fabric returns to its relaxedstate.
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Banding
Defect created by the print heads movement over the substrate.
Use of scanning print head, or a print head that moves back andforth across the substrate in straight line placing drops of ink at
precise locations along the line.
If the head is not properly aligned, or if the substrate advances
unevenly, the result is a slight horizontal band or line of
unprinted area.
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Unwanted pigment
marking on fabric
Caused due to screen has holes
in it that should have beencovered. This could be because
of ageing of the screen and
eventual damage or just
improper exposure to light.
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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.
Color Smear
The result of color being smeared during printing.
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Color Out
The result of color running low in reservoir on printing
machine
Mottled
Color applied unevenly during printing
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Crack or miss alignment in
transfer printed fabric.
Incomplete transfer of design
from paper to fabric on transfer
printing due to removal of
transfer of paper while the
fabric was still hot.
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Finishing Defects
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FABRIC FINISHING
A series of processing operations applied to
gray fabrics to enhance their appearance and
hand, properties and possible applications.
Play a fundamental role for the commercial
excellence of the results of textiles
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FABRIC FINISHING
The most simple form of finishing is theironing or pressing on the fabric.
In finishing , the fabric is subjected to
mechanical and chemical treatment in which
its quality and appearance are improved and
its commercial value enhanced.
Physical finishing techniques(dry finishing
processes) or chemical finishing methods(wetfinishing) are used.
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FABRIC FINISHING
Functional finish:
Wearability, Hand, Mechanical resistance,
Easy care, Wettability, Washability,Deformability, Anti bacterial, Anti fungal,
Soil-proof and Fire-proof ability
Aesthetic finishes:
Aesthetic looks
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Unwanted marks on
fabric.
Oily stains with dust adhered to
surface which makes the stains
more prominent and difficult to
remove, due to contact with oil
or grease covered exposed
machine parts, careless handling
could be another cause.
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Decolorized patch on fabric
Caused due to
chemical spillage on fabric.
Localized excess bleaching.
Localized excess enzyme wash.
Can be result into weakening of
the fabric.
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Pin Holes
Holes along selvage caused by pins holding fabric while it
processes through tenter frame.
Major defect if pin holes extend into body of fabric far enough
to be visible in the finished product.
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Sanforize Pucker
Results from uneven wetting out on sanforize.
usually caused by defective spray heads.
Fabric will appear wavy or puckering when spread on cutting
table.
Difficult to detect during inspection on inspection machine
with fabric under roller tension.
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Bowing
Usually caused by finishing.
Woven filling yarns lie in an arc across fabric width; in knits
the course lines lie an arc across width of goods.
Establish standards of acceptance. Critical on stripes or
patterns; not as critical on solid color fabrics.
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Pilling
Pilling is a common fabric defect occurring on knitted and
woven fabrics.
In producing a yarn, long fibers tightly-twisted produce a
serviceable yarn. When short stable fibers are mixed into the
yarn the result is a yarn that will not hold together. The short
staple fibers will separate from the yarn and curl up in a ball,
forming what is referred to as a pill.
Pilling is accentuated by the friction of normal wear, washing
and routine dry cleaning.
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Water Spots
Usually caused by wet fabric being allowed to remain too long
before drying; color migrates leaving blotchy spots.
Selvage Torn
Usually caused by excessive tension while processing through
tenter frames.
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Cuts or Nicks
Caused by indifferent handling of scissors. snips or
mechanical trimmers.
Seam Tears
Frequently caused by the turning equipment used to
reverse garments in finishing.
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Soil
Caused by oil, grease or dirt. Often times originating
from a dirty work area or machinery not properly
cleaned
Streaks
Markings caused by some types of turn boards ordefectively finished trimming.
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Inadequate Pressing
Caused by excessive heat or pressure resulting in poor
pleating, fullness or twisting of a seam on garment surface.
Pressing Producing Shine on Fabric
Usually caused by excessive heat or incorrect type ofpressing surface.
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Loose threads
Loose threads will get wound on guide rollers forming ridges
in the processing machines and cause creases at these places.
Also loose threads can cause problems of Dye /Print transfer
in a padding / Printing application
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Askewed or Bias
Condition where filling yarns are not square with wrap yarns
on woven fabrics or where courses are not square with wale
lines on knits.
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Folding Defects
Garment not Folded to Specifications
Garment not Folded with proper Materials:Cardboard, tissue or other specified packaging materials
omitted
Garments not Buttoned, Flys not Closed, IncorrectNumber of Pins
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Thank You.
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