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Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
Fundamentals of denim & faults in rope dyeing
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Fundamentals of denim & faults in rope dyeing

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  • 1. Southeast University Department of Textile Engineering Fundamentals of Denim & Faults in Rope Dyeing 14/09/2011
  • 2. Name : MAZADUL HASAN SHESHIR ID: 2010000400008 Batch: 13th Batch (Session 2009-2013) Department: Wet Processing Technology Email: mazadulhasan@yahoo.com Blog: www. Textilelab.blogspot.com Southeast University Department of Textile Engineering PREPARED BY ©right
  • 3. Southeast University Department of Textile Engineering  To know about fault of each process .  To know what is the cause of this faults .  To know about remedies of each faults .  Quality improvement of the product .  Fault analysis. Objective of t he project: Fundamentals of Denim & Faults in Rope Dyeing
  • 4. Southeast University Department of Textile Engineering  Typical denim fabrics are woven from coarse indigo dyed cotton yarn .  They are hard weaving high density fabrics with a high mass per unit area.  Denim is produced more in the world than any other type of cloth .  It is made for a variety of application and in a wide range of qualities and shades.  Even today, classic denim is still dyed with indigo.  It is a special process in which only the surface of the warp yarn is dyed & the weft stays white.  This is why the garment subsequently develops the typical and desired signs of wear. What is Denim ? 14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing
  • 5. Southeast University Department of Textile Engineering  Drivability---excellent  Luster----good  Texture---cotton, thus excellent for clothing  Absorbency----excellent. Looks good wet, clings.  Durability----excellent. Stands up to heavy wear and abuse.  Resilience----excellent. Tough fabric, stands up to washing.  Flammability----Can be treated to be less flammable, but is cotton.  Fabric source----Cotton Examples of end use---jeans, skirts, shirts, jackets. Most popular clothing material in the world. 14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing The properties of denim are as follows :
  • 6. Southeast University Department of Textile Engineering 1. Stone washed a). Single stone washed b).Double stone washed 2. Chambray 3. Fancy with multi color denim 4. Denim with metal effect 5. Elastic denim 6. Printed denim 7. Jacquard patterned denim 8. Denim with fancy yarns 14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing Denim can be classified as follows :
  • 7. Southeast University Department of Textile EngineeringMostly use type of Denim Fabric  Cotton Serge  Raw Denim  Selvage Denim  Stretch Denim  Poly-D enim  Ramie-Denim 14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing Type of Denim dyeing process :  Indigo rope dyeing process  Indigo one sheet dye slashing  Indigo double sheet dyeing  Loop dye 1 for 6 (continuous dye slashing)  Loop dye 1 for 6 with dyemer (continuous mercerization dyeing and sizing).
  • 8. Southeast University Department of Textile EngineeringDeference between slasher dyeing vs rope dyeing : Slasher Dyeing Rope Dyeing 1. Required less floor space 1. Required more floor space 2. It is a continuous process 2. It is not a continuous process 3. The mercerizing process is easy and simple 3. In Rope dyeing mercerizing is difficult 4. Required less manpower 4. Required more man power 5. The capacity of dye bath is 100 liter 5. The capacity of dye bath is 2500 liter
  • 9. Southeast University Department of Textile Engineering Flow chart of denim fabric procedure: Ball Dyeing Long chain beamer Sizing Weaving Finishing Ball Dyeing Long chain beamer Sizing Weaving Finishing
  • 10. Southeast University Department of Textile Engineering Faults in warping: Fundamentals of Denim & Faults in Rope Dyeing Problems Causes Remedies 1. Lot variation 1. Several lot yarn come from spinning mill . 1. Yarn cone must be tested before production . 2. Chain breakages. 2. Irregular maintenance of chain spoke & gear. 2. Proper maintenance & lubrication of the chain gear and spoke. 3. Thermal damages . 3. Improper lubrication. 3 frictional dnun should not be kept in a polished state.
  • 11. Southeast University Department of Textile Engineering Fundamentals of Denim & Faults in Rope Dyeing Problem Cause Remedies 4. Sprockets are jammed 4. Hydraulic system does not work properly. 4. Proper lubrication must be done . 5. Irregular movement of the comb. 5. It causes breakages or loosening in yarn. 5. Reduce the hydraulic friction by using lubricants 6. Tension variation in yarn. 6. If speed of warper increase. 6. Check the tension of the tension disk Continue:
  • 12. Southeast University Department of Textile Engineering Fundamentals of Denim & Faults in Rope Dyeing Problems Causes Remedies 1. Leakage of steam in drying cylinders. 1. Not proper working the steam valve 1. Proper maintenance has to done of the pressure valve. 2. Wear and tear of rollers 2. If bearing is jamed 2. Lubricant have to use . 3. Entanglement of rope. 3. Improper working of load cell oil squeezing roller. 3. Pressure has to distribute properly. Dyeing faults:
  • 13. Southeast University Department of Textile Engineering Fundamentals of Denim & Faults in Rope Dyeing Problems Causes Remedies  4. Shade variation. 4. Faults in dosing        system 4. Dosing pump,filter, outer have to           maintenance properly. 5. Broken yarn in tile        rope. 5. Improper alignment       of the yarn in the         rope. 5. Change the pressure of theguide        roller. 6. Irregular rope. 6. Improper alignment       of the  rope 6. Guide roller has to work properly. Continue:
  • 14. Southeast University Department of Textile Engineering Fundamentals of Denim & Faults in Rope Dyeing Problems Causes Remedies 1. Pressure rollers do        not work properly. 1. Incorrect shaft       adjustment, whipe     roller covering, shed       closure wrong 1. Shaft adjustment ,Whipe roller   covering have to done properly 2. Squeezing rollers do        not work properly 2. Incorrect shaft        adjustment 2. Shaft adjustment have to check         Properly 3. Size dust-off 3. Size chemicals are not         properly mixed . 3. Size box have to accommodate in        a Proper condition Faults in sizing:
  • 15. Southeast University Department of Textile Engineering Fundamentals of Denim & Faults in Rope Dyeing Problems Causes Remedies     BENT PICK  1. Catch cord is not        working properly 2. Air pressure of nozzle        is insufficient. 1. Check catch cord drawing in and        its position 2. Air pressure of all nozzles     WEFT PATTI 1. Piston is not working        properly 2.  Missing gear of      slippage of pinion 1. Check  piston 2. Check beam gear and beam        drive pinion Faults in Weaving:
  • 16. Southeast University Department of Textile Engineering Fig: Bent Pick Fig: Weft Patti Fig: Weft Float Fig: Missing End
  • 17. Southeast University Department of Textile Engineering Problems Causes Remedies WEFT FLOAT 1. Air pressure Variation 2.   Damage of air pipe 1. Check Air pressure 2. Check leakage of air pipes   MISSING END 1. Serrated bars are      loose contact 2. Dropper sensitivity is          not working properly 1. Check all serrated bars are not in         loose contact at the clamp 2. Dropper sensitivity to be       checked TORN OR HOLE AT  THE TEMPLE 1. Tight or loose warp       tension 2. Temple cover is not       accurate position 1. Check warp tension 2. Check that temple cover is face to       face with temple bracket Continue..
  • 18. Southeast University Department of Textile Engineering Fig: Torn or Hole at the Temple Fig: Missing Pick Fig: Tight Ends Fig: Abrasion Mark
  • 19. Southeast University Department of Textile Engineering Problems Causes Remedies ABRASION MARK 1. Cross end problem 2. Tight heald wires 1. Check cross ends 2. Check freeness of heald wires. MISSING PICK 1. Wrong feeler timing in I- board 2. Unsufficient air pressure 1. Check feeler timing in I-board 2. Check setting of FU TIGHT ENDS 1. Unparallel warp yarn 2. Entangle warp yarn 1. Check that ends should be parallel 2. Remove entanglement of warp ends Continue..
  • 20. Southeast University Department of Textile Engineering Problems Causes Remedies OIL DAGHI 1. Oily fluff stuck on the warp sheet 2. Oily fluff on the emery roll 1. Check that no oily fluff is stuck to the warp sheet 2. Check that no oily fluff is stuck to the emery roll or pressure roll BALL FORMATION 1. Short fiber deposited in warp yarn 2. Sub deposit. 1. Air suction pump have to work properly 2. Yarn must be examined before production BAD SELVEDGE 1. Fault in stop motion 2. Faulty RH cutter 1. Check leno stop motion 2. Check proper RH cutter setting Continue:
  • 21. Southeast University Department of Textile Engineering Fig: Oily Warp Fig: Ball Formation
  • 22. Southeast University Department of Textile Engineering Remark  In this experiment we learn more think about the denim dyeing process.  It is very helpful our next life to work in the denim dyeing unit  At lest thank to our respected Course teacher to give me the opportunity to work this type of wonderful experiment 14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing Reference:  Understanding Textile for a Merchandiser  Envoy Textile Ltd.  www.scribd.com

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