Fabrics faults and remedy

Southeast university

DEPERTMENT OF TEXTILE ENGINEERING

April 10, 2023 AKL and GMS 1

Company profile Name of the Company: Alim Knitwear ltd Year of Establishment: 2005-2006 Certified Achievement: ISO 9001:2000, (Certified), Oeko-Tex Standard 100 (Certified) Manufacturing products: Export oriented knit fabrics dyeing and readymade garments Owner and directors of the factory: Alim mondal. Factory Address: Nayapara, Kashimpur, Gazipur, Bangladesh Total Employees: 4500 Number of units: 3 (Three) units Part-A: Garments unit – 3 floors Part-C: Dyeing unit Part-D: Printing unit Total area: 0.5 acres Corresponding Bank: 1) United Commercial Bank Limited . Dhaka, Bangladesh

2) Dutch Bangla Bank Ltd. Dhaka, Bangladesh Factory Supervisor: Md. Mamun ( PM in garments section) Supervising teacher: Md. Abul Kalam Azad.


Another Name of the Company: GMS composite Knitting industries ltd. Year of Establishment: 2003-2004 Certified Achievement: ISO 9001:2000, (Certified), Oeko-Tex Standard 100

(Certified) Manufacturing products: Export oriented knit fabrics dyeing and readymade

garments Owner and directors of the factory: GMS composite Knitting industries ltd. Factory Address: Ssaradagong, Kashimpur, Gazipur, Bangladesh Total Employees: 4500 Number of units: 3 (Three) units Part-A: Garments unit – 3 floors Part-C: Dyeing unit Part-D: Printing unit Part-E: knitting unit. Factory Supervisor: Md. Saiful Islam


Object of training To know about garments faults & remedy we

justify each & every garments. To knowing that we give max customers

satisfaction. To know about different fabric inspection. To know about different quality parameters of

fabric, different trims & accessories. To know about buyers AQL. To know about major or minor fabric faults.


Methodology of textile faults.

For Yarn manufacturing technology:

We study different types of yarn faults, causes and its remedy.


Faults name Causes Remedy

1. Slub Lack of adequate fibre control in the drafting Zone.

Proper fibre control of drafting zone

2. Oily slub Improper lubrication proper lubrication

3. Kitty yarn Improper ginning i.e. Seeds broken during ginning

proper ginning i.e. Seeds broken during ginning

1. Slub

2. Kitty yarn




4. Foreign matters Improper handling of travelersImproper preparation of mixing

proper handling of travelersproper preparation of mixing

5. Soft yarn Improper bobbin feed on the spindlesLess twist in the yarn

proper bobbin feed on the spindlesProper twist in the yarn

6. Crackers Mixing of cotton of widely different staple lengthsCloser roller settings

Proper Mixing of cotton of widely differing staple lengthsProper roller settings

Spinning faults and remedy percentage diagram


Sl = slub yarnOi = oily slubKi = Kitty yarnFo = Foreign matterCo = cork screw yarnOv = over twisted yarnSo = soft yarnCra = cracker

Rem

edy %

Faults name

Knitting faults, causes and its remedy:


1. Barre Caused by mixing yarn on feed into machine.

Proper yearn selection and proper roller adjustment.

2. Broken Colour Pattern

Usually caused by color yarn out of place on frame.

Proper adjustment of color and yarn.



3. Crease mark Its create when fabric passing through squeeze rollers in the dyeing process. Its mainly Occurs in tubular knits fabric.

Proper adjustment of squeeze rollers.

4. Hole caused by broken needle Change the needle.

5. Needle Line Caused by broken needle forming distorted stitches

Replace the needle




6. Runner Usually caused by broken needle.

Change the needle.

7. Slub (Knit fabric) Usually caused by a thick or heavy place in yarn

Replace the yarn cone to a more uniform yarn cone.

Different Causes of Fabric Barre


Knitting faults and remedy percentage diagram:

April 10, 2023 AKL and GMS 13R

emedy %

Ba = barre markBro = broken colorMis = missing yarnMix = mixing yarn

Dyeing, printing and finishing faults and remedy

Classification of Defects Minor Defect A defect is defined as minor Defect that is not likely to reduce the Usability

of the product, but nevertheless may negatively influence the sales. The minor defects can be untrimmed thread-ends, slight dirt in a non-

noticeable zone which can be removed, etc 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.



1. Barre Its horizontal shaded band across the width of the fabric. It causes by the yarn mixing

proper yarn selection.

2. Bleeding improper dye selection or poor dye fastness.

proper dye selection.

3. Crocking It is the rubbing off of the color.It may rub onto another fabric.

proper dye selection.


barre Bleeding Crocking


4. Shading It is generally due to uneven tension on the fabric.

To maintain the proper tension

5. Stained caused by a foreign substance, dirt, grease, and oil or sizing residue on the fabric being dyed.

To using different spot remover chemical

6. Color variation in yarn

Caused due to lack of agitation in the dye bath

proper agitation in the dye bath.


Shading stained Color variation yarn



7. Creasing Causes unleveled penetration of dyes

To use proper dyes and chemical or leveling agent.

8. Flushing/Wicking Caused due to Low viscosity of print paste

To use high viscosity of printing past

9. Bleeding Caused due to Low viscosity of print paste

To use high viscosity of printing past.

Creasing Flushing Bleeding


10. Crack or miss alignment in transfer printed fabric.

Incomplete transfer of design from paper to fabric

Proper transfer of design.

11. Unwanted marks on fabric. Causes by the contact with oil or grease covered exposed machine parts, careless handling

To using spot cleaner.

12. Decolorized patch on fabric Caused due to chemical spillage on fabric. Localized excess bleaching. Localized excess enzyme wash.

To using spot cleaner.


Crack Unwanted mark Decolorized patch on fabric

Dyeing and printing faults and remedy percentage diagram


Rem

edy %

Bar = barreBl = bleedingSh = shaddingRu = running shadeCrea = creasing Un = unwanded markFlu = flushing Crak = crack or miss aligment

Garments faults and remedyFaults Name Causes Remedy 1. Misprints or off registration. not properly cleaning of Printing

screens .Properly Cleaning of printing screen.

2. Grease/ Oil / dirty stains. Oil stains generally come from sewing machines; machines such as over lock and flat lock machines are more prone to have oil stains.

To use spot cleaner chemical

3. Needle damage. using the wrong needle. Repairing or older the garments

4. Open or broken seams improper handling of the cut piece or machine

Repairing or alter the garments.


Misprint Grease/ oil/ dirty stain. Needle damage Open or broken seam

Faults name Causes Remedy 5. Broken stitch improper handling of cut pieces or

improper machine usage.Repairing or alter the garments

6. Skipped or dropped stitches improper handling of cut pieces or improper machine usage.

Repairing or alter the garments

7. Neck shape. caused by defective cut pieces. Repairing or alter the garments or use proper cut piece of garments.

8. Sewing thread not matching. To use improper sewing thread. To use proper sewing thread.


Broken stitch Skipped stitch Neck shape Sewing thread not matching

Faults name Causes Remedy 1. Seams not aligned at crossing of seams.

improper handling of the cut piece. Repairing or older the garments.

2. Stripes not matching. from improper handling of cut pieces.

Repairing or older the garments.

3. Misplaced label improper placement of labels when sewing

Repairing or alter the garments or proper placement of the label.


Seam not aligned at crossing of seams Stripes not matching Misplaced label

Garments faults and remedy diagram


Dir = dirty stain Bro = broken stitchSkip = skip stitchSw = sewing thread not matchMiss = misplace labelNec = neck shapePo = pocket dispositionUn = uncovered seamBrok = broken seam

Conclusion

In Bangladesh the maximum dyeing industry are knit dyeing Industry. So these kinds of industries are often suffering by these Faults which tend to not fulfill the target of production. As a result the production capacity of these industries falls significantly. These are the common faults which I have tried to find out the causes & their Remedies against them.


Fabrics faults and remedy

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