Dyeing Faults Causes and Remedies

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Dyeing faults causes and remedies

 Dyeing Faults Causes and Remedies

Dyeing Faults:

Major dyeing faults in dyeing process is mentioned as follows.
  1. Uneven Dyeing
  2. Batch to Batch Shade Variation
  3. Patchy Dyeing Effect
  4. Roll to Roll Variation or Meter to Meter Variation
  5. Crease Mark
  6. Dye Spot
  7. Wrinkle Mark
  8. Softener Mark

Uneven Dyeing:
Uneven dyeing causes and remedies
Fig: Uneven Dyeing

Causes:

  • When uneven pretreatment occurs (i.e. uneven scouring and bleaching)
  • Improper color dosing in the dye tank
  • When high fixation dyes uses
  • In case of synthetic fibers, uneven heat setting
  • Lack of maintenance of dyeing machine

Remedies:

  • Ensure even pretreatment
  • Ensure even heat-setting in the case of synthetic fibers
  • Proper dosing of dyes and chemicals
  • Proper controlling of dyeing machine.

Batch to Batch Shade Variation
Batch to batch shade variation causes and remedies
Fig: Batch to Batch Shade Variation

Causes

  • Temperature fluctuation
  • Dyes and chemicals improper dosing time
  • Dyes and chemicals batch-to-batch weight variation 
  • Variation of dyes lot
  • Improper liquor ratio, reel speed, pump speed
  • Improper pretreatment 

Remedies:

  • By using standard dyes and chemicals
  • The same liquor ratio needs to be maintained
  • By following standard pretreatment procedure
  • The same dyeing cycle needs to maintain
  • An identical dyeing procedure should be followed
  • The operators need to add the right bulk chemicals at the same time and temperature in the process
  • The pH, hardness, and sodium carbonate content of supply water should check daily

Patchy Dyeing Effect
Patchy dyeing effect causes and remedies
Fig: Patchy Dyeing Effect

Causes

  • Fabric entanglement
  • Alkali faulty injection
  • Color improper addition
  • Due to water hardness
  • Due to the addition of improper salt
  • During intermediate dyeing, dye migration
  • Uneven heat in the machine etc.

Remedies:

  • Proper pretreatment needs to be ensure
  • Dyes and chemicals proper dosing
  • Heat should be the same throughout the dye liquor
  • Proper addition of salt

Roll to Roll Variation or Meter to Meter Variation

Causes

  • Dyes poor migration property
  • Improper solubility of dyes
  • Water hardness
  • Faulty machine speed, etc.

Remedies

  • Use of standard dyes and chemicals 
  • Proper machine speed need to maintain
  • Use of soft water

Dye Spot
Dye spot causes and remedies
Fig: Dye Spot

Causes

  • Dye particles improper dissolving in batch
  • Caustic soda particle improper dissolving in bath

Remedies

  • Dyes and chemicals need to be properly dissolve
  • Bypassing the dissolved dyestuff through a fine stainless steel mesh strainer

Crease Mark

Crease mark causes and remedies
Fig: Crease Mark


Causes

  • The fabric rope poor opening
  • Synthetic material shock cooling
  • If pump pressure & reel speed in not equal
  • Due to high speed machine running

Remedies

  • Proper reel speed and pump speed maintaining
  • Lower rate rising and cooling temperature
  • Reducing machine load
  • Higher liquor ratio

Wrinkle Mark
Wrinkle mark causes and remedies
Fig: Wrinkle Mark

Causes

  • The fabric rope poor opening
  • Shock cooling synthetic material
  • High temperature entanglement of the fabric

Remedies

  • Maintaining of proper reel and pump speed
  • Cooling the temperature and lower rate rising
  • Liquor ratio need to be remain higher

Softerner Mark
Softener mark causes and remedies
Fig: Softener Mark

Causes

  • Softerner improper mixing
  • During application of softener, improper fabric running time
  • Fabric entanglement during application of softener

Remedies

  • Proper reel speed and pump speed should be maintained
  • Proper mixing of softener before the addition of the softener
  • During softener application, prevent the entanglement of the fabric

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