Grey Inspection in Textile Wet Processing


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Grey Inspection in Textile Wet Processing

  1. 1. 05-Jan-12 Inspection Definition: Grey Inspection Activities such as Measuring, Examining, Testing, Gauging, one or more characteristics of a product or source comparing these with specific requirements to determine conformity. Aravin Prince Periyasamy Dept of Textiles, DKTE TEI, Ichalkaranji, MH, India 2  Grey cloth from weaving have many faults ( Broken ends and Principles picks, stains and etc) 3c’s Of Inspection Every Inspection Is Involving 3c’s .  Many of these faults can be corrected at grey stage before wet Check, Compare & Conclude processing .  Also in grey inspection following points are checked,  EPI, PPI, Width and Length of fabric & GSM. Inspection Instruments / Tools Types of Inspections The assessment may be carried out usually or by  Pick glass  Measurement by tape  Flow Based  Visual  UV lamp  Streak analyzer  Point Based  Spotting with Shirley stain or similar staining agents5 1
  2. 2. 05-Jan-12 Flow Based Fabric Inspection Point Based Fabric Inspection  Minor Faults: 1 defects within 15 CM is considered as a minor faults. Fabric Inspection:  Major Faults: Within 15 CM More than 1 defects is considered as a Major Defects There are Three types……  Selvedge Defects • 4 Point system Incase of furnishing fabric minor selvedge defects like pulled in selvedge are considered as major defects • 10 Point system • Mil- Standards  Small defects are nearer to the selvedge means, it will not considered to the serious problem. 8 4 – Point System Four Point System In ’4 Points’ system of grading, faults are scored with penalty of 1, 2, •Maximum of 4penalty points can be assigned for any single defect 3 and 4 according to the size and significance Size of Defect Penalty Points - no linear yard / meter can be assigned more than 4 points regardless of number of defects within the yard/meter. Upto 3 inches 1 •Employing the following criteria: >3” to 6” inches 2 The defects in both wrap/weft, course/wale directions will be assigned points >6” to 9” inches 3 Above 9 inches 4 10 10 Point System Point count calculation For Individual Roll: •In ’10 Points’ system of grading, faults are scored with penalty of 1, 3, 5 and 10 according to the size and significance Size of Defect Penalty Points Points per 100 Sq. yards = Total linear points x 3600 1 inches or less 1 Length in Yds x Fabric width in inches Over 1” but not over 5” 3 Over 5” not over 10” 5 Over 10” / full width 10 12Application 2
  3. 3. 05-Jan-12Eg (Calculation) Different Color Tags for Different Processes & Defects  Knitted fabric length is 58 yds, width 60 inch for inspection. Following defects and points can be found (4 –Point Method), Size of Defects Defects Total Points  In export two types of tag used Upto 3 Inch 2 2X1= 2 3- 6 Inch 3 3X2= 6  Red tag 6 – 9 Inch 2 2X3= 6 It represented the critical defects More than 9 Inch 1 1X4= 4 Total Points Earned 18 Points  White tag Points per 100 Sq. yards = Total linear points x 3600 Length in Yds x Fabric width in inches It represented minor defects (add 10 CM of fabric wherever defects • Points / 100 Sq Yds = 18 X 3600 is present) • 58 X 60 • Points / 100 Sq Yds = 18.63 • As per the standard less than 40 points / 100 sq yds is considered First Class • As per the standard more than 40 points / 100 sq yds is considered Second Class Knitted Woven Woven fabric inspection Barre Bar Birdseye Broken ends Broken pattern Broken picks Run Burl marks Skip Stitch Coarse End/Pick Dropped stitches Crack End out Misdraw Float Fly waste Some Missing yarn Mixed Yarn Jerk-in Knots Common Needle Line Off Pattern Fabric Defects Press off Reed Mark Slack end Slough off Slub Smash Soiled / Oily Filling Processing Defects : Bow/Skew, Color Out, Color Smear, Doctor Streak, Dye Stain, Out of register, Sanforize pucker, Seam impression, Scrimp 16 Advantages End of roll automatic stop sensor - For next roll joining This will allow for efficient continuous inspection, from roll to roll. Accurate fabric length and optional weight measurements Fabric roll length and weight can be taken using industrial standard measuring systems with digital readouts to give consistent fabric roll assessments. Auto adjustable tension Automatic adjustable tension of fabric when rewinding. Data collection and analysis system - With fabric fault tagging 100% fabric inspection with simple push-button accurate fault logging, roll length and weight measurement allowing for accurate fabric roll analysis and printout. 3
  4. 4. 05-Jan-12Knitted Fabric Inspection Contamination Dirt soil Holes Shade variation Miss Print 4