PRESENTATION NAME

Dyeing And Printing Defects Analysis1Classification Of DefectsMinor Defect A defect is defined as minordefect that is not likely to reduce theusability of the product, but neverthelessmay negatively influence the sales.

The minor defects can be untrimmedthread-ends, slight dirt in a non-noticeable zone which can be removed, etc.Classification Of DefectsMajor 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. Dyeing DefectsCauses Of Dyeing DefectsDue 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.

Causes Of Dyeing DefectsDue 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.BarreIts horizontal shaded band across the width of the fabric. It may be caused by variation in the size of the filling yarn and by the differences in tension of either the filling or warp yarns.

BleedingIts a loss of color when the dyed fabric is wetted or emerged in water.

The water here, becomes colored and may cause discoloration of other fabrics.

This is usually due to either improper dye selection or poor dye fastness.

Crocking It is the rubbing off of the color.It may rub onto another fabric.This may be due to inadequate scoring subsequent to dyeing.

Shade BarIt 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

Shading It is a variation in color tone either horizontally or vertically.It is generally due to uneven tension on the fabric.

Stained It indicates a discoloration caused by a foreign substance, dirt, grease, oil or sizing residue on the fabric being dyed.

Color variationin yarnCaused due to lack of agitation in the dye bath.This is a major defect. The yarn was supposed to be uniformly blue in color.

Hole in sulfurdyed fabricCaused 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.

CreasingCauses unleveled penetration of dyes which in turn results into unleveled dyeing, which causes colour variation.Differs from crease streak in that streak will probably appear for entire roll. On napped fabric, final pressing may not be able to restore fabric or original condition. Often discoloration is a problem.

Off ShadeIt refers to color that doesn't exactly match the standard or the prepared sample.This may be due to faulty dye foundation or application or may be due to variation in dye lot.Streaked This type of defect on the fabric indicates either a stain or uneven dyeing caused by folds in the fabric during the dyed process.Printing DefectsMethods of PrintingBlock

Stencil

Screen

Flat Press

RollerFlushing/WickingCaused due to Low viscosity of print paste.

It occurs when the printed area bleeds out into the unprinted area. The result is a haloing or shadowing effect around the outline of the pattern design.

BleedingCaused due to Low viscosity of print pasteIt is major defect as it happens throughout the fabric unless the viscosity is corrected.

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. Stick-insA 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.

ScrimpsA 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 relaxed state.

BandingDefect created by the print heads movement over the substrate.

Use of scanning print head, or a print head that moves back and forth 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.

Unwanted pigmentmarking on fabricCaused due to screen has holes in it that should have been covered. This could be because of ageing of the screen and eventual damage or just improper exposure to light.

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. Color Out The result of color running low in reservoir on printing machine Mottled Color applied unevenly during printing 28Crack 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.

Finishing DefectsFABRIC FINISHINGA 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

FABRIC FINISHINGThe most simple form of finishing is the ironing 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(wet finishing) are used.

FABRIC FINISHINGFunctional finish:Wearability, Hand, Mechanical resistance, Easy care, Wettability, Washability, Deformability, Anti bacterial, Anti fungal, Soil-proof and Fire-proof ability

Aesthetic finishes:Aesthetic looks

Unwanted marks onfabric.Oily stains with dust adhered tosurface which makes the stainsmore prominent and difficult toremove, due to contact with oil or grease covered exposed machine parts, careless handling could be another cause.

Decolorized patch on fabricCaused due to chemical spillage on fabric.Localized excess bleaching. Localized excess enzyme wash.Can be result into weakening of the fabric.

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. 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. 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. 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. 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. Cuts or NicksCaused by indifferent handling of scissors. snips ormechanical trimmers. Seam Tears Frequently caused by the turning equipment used to reverse garments in finishing.SoilCaused by oil, grease or dirt. Often times originatingfrom a dirty work area or machinery not properlycleanedStreaks Markings caused by some types of turn boards or defectively finished trimming.Inadequate PressingCaused 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 of pressing surface.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 applicationAskewed 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. Folding DefectsGarment 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 PinsThank You.