Fabric Faults & Remedy-Updated

MD. SAIDUL HAQ MASUM
Production Officer (Weaving)
Ha-Meem Denim Ltd.
Page 1 of 21
ARTICLE ON:
FAULTS IN WOVEN FABRIC &
THEIR REMEDY
Prepared By:
B.Sc. In Textile Engineering (CU)
MBA In Textiles (BUTex) [Ongoing]
Ha-Meem Denim Ltd.
Mawna, Sreepur, Gazipur.
e-mail: saidulhaqmasum.butex@gmail.com
Preface:
This article has prepared based on my practical findings about faults in
woven (denim) fabrics. Here I have focused on the frequently occurring
weaving faults in woven (denim) fabrics. I hope this article will be helpful
for any kind of research & development related with woven fabric faults &
heir recovery.t
I am specially thanking to the authority of Ha-Meem Denim Ltd.
Friday, June 14, 2013

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FAULTS IN WOVEN FABRI &
THEIR REMEDY
The international textile market is quite quality sensitive. Therefore to have
a sound knowledge about the quality of textile products is essential for the
person oriented with the textile manufacturing & marketing. Here I am
going to focus on the faults of woven fabric & their recovery procedure.
The frequently occurring faults in weaving can be categorized as follows:
a) Faults related with Warp.
b) Faults related with Weft.
c) Faults related with loom operation.
d) Faults due to poor vigilance.
e) Miscellaneous faults.
The frequently occurring faults in weaving are enlisted bellow according to
their category:
a) Faults Related With Warp:
In this category the following faults exist:
1. Double Ends.
2. End Out/Miss Warp.
3. Wrong Drawing-In.
4. Wrong Denting.
5. Balls.
b) aults Related With Weft:F
6. Snarls.
7. Broken Pick.
8. Miss Pick.
9. Weft Yarn Fault.

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c) aults Related With Loom Operation:F
10.Starting Mark.
11.Temple Mark.
12.Line Mark.
13.Crease Mark.
d) Faults Due To Poor Vigilance:
14.Weft Yarn Count Mistake.
15.Weft Yarn Ratio Mistake.
16.Unwanted Slub In Weft.
17.Slub Miss In Weft.
e) Miscellaneous Faults:
18. Gout.
The causes of formation of these faults & their recovery procedures are
described bellow in detail.
a) Faults Related With Warp:
1. Double Ends:
When two adjacent warp ends are drawn through the same heald eye, then
those two ends are woven in the same weave & faulty fabric is produced.
This fault is known as double ends.
Causes:
■ The most vital cause of double ends is incorrect drawing. Always each
warp ends should be drawn through each heald eye. But if two adjacent warp
ends are drawn through the same heald eye, then it will result the formation
of double ends.

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■ Double ends can also be resulted due to the negligence during warping or
sizing. When any end is being broken during warping or sizing; then it
should be mended (re-knotted) with the respective end. But sometimes the
operators of warping or sizing don’t do that. Rather they wrap that broken
end with an adjacent end to save their time. As a result, when that end
reaches to the heald eye, it enters into the heald eye with the other end with
which it wrapped. As a result double end is being woven.
Remedy:
■ Drawing-in should be done very carefully.
■ If any end is being broken during warping or sizing, it should be mended
re-knotted) with the correct respective end.(
■ The operators should have to be trained & careful. As they can find any
ouble ends& can mend it right there.d
■ Vigilance in the weaving floor should be increased in such a level that no
double ends can run for a long time. That means, when a double ends just
passes the weaving zone, it should be find out & mend right there.
2. End Out/Miss Warp:
When any warp end is missed in the woven fabric, then it is called end out or
missed warp.
Causes:
■ The main cause of end out is the malfunction of warp stop motion. Now a
days all kinds of automatic & semi-automatic looms are provided with warp
stop motion. Vital working elements of warp stop motion are electrode &
drop-wires. The purpose of warp stop motion is to stop the loom
immediately just then, when any warp yarn is broken. Each warp end is
being drawn through the drop-wires. The drop-wires remain under tension
by the warp ends & therefore they can’t touch the electrode. As any warp
end breaks, the corresponding drop-wire falls on the electrode & shorts the
two metal parts of the electrode; that sends a signal to the processor of the
loom & stops the loom immediately.
Now if the drop-wire fails to touch the electrode when a warp end is being
broken, then the loom will continue to run with the broken end. This will

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cause to woven the fabric with a missing end; that means the fault- end out
will be resulted.
The described phenomenon happens when the drop-wires & electrode are
being blocked by dust or any kind of other non-conductive substances.
■ End out can also be caused due to drawing-in any warp end through the
heald eye without drawing that yarn through drop-wire.
Remedy:
■ Loom should be kept neat & clean; so that the warp stop motion doesn’t
malfunction. The operators should be ordered strictly to clean the drop wires
&electrode properly after a regular periodic interval by directing compressed
ir.a
■ During drawing-in it should be confirmed that each warp end has drawn
hrough drop-wires.t
■ Vigilance in the weaving floor should be increased in such a level that
when an end out just occurs, it could be find out & mend right there.
3. Wrong Drawing-In:
The fault in a woven fabric that is caused due to the incorrect order of
drawing-in is called wrong drawing-in. Drawing-in is done according to the
Drafting Plan. Drafting plan is a graphical instruction that indicates which
warp end will be drawn through heald wire of which heald shaft. The
described tropics will be clear with some practical illustrations. So let us
have a look to the following designs on page-6 & 7.
There are 3 designs. The drafting plan of design-A (3/1 Right Hand Twill) &
design-B (3/2 Vertical Herringbone) are Straight Draft, where the no. of
heald shafts is equal to the no. of ends in the repeat. The drafting plan of
design-C (3/3Dimond) is “V” Draft, where the no. of heald shafts is half of
the no. of ends in the repeat.

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↑
S
H
A 4 → → → → → → → Shafts 1 2 3 4
F 3 → → → → → → ↓
T 2 → → → → → ↓ ↓ E * 1 2 3 4
S 1 → → → → ↓ ↓ ↓ N
↓ ↓ ↓ ↓ D * 5 6 7 8
↑ 4 4 S
P 3 3 → Up (Warp Yarn) * 9 10 11 12
I 2 2 To
C 1 1 → Down (Weft Yarn) Be * 13 14 15 16
Ks # 1 2 3 4 1 2 3 4
D * 17 18 19 20
R
AW * 21 22 23 24
N
10 → → → → → → → → → → → → → →
9 → → → → → → → → → → → → → ↓
8 → → → → → → → → → → → → ↓ ↓
↑ 7 → → → → → → → → → → → ↓ ↓ ↓
S 6 → → → → → → → → → → ↓ ↓ ↓ ↓
H 5 → → → → → → → → → ↓ ↓ ↓ ↓ ↓
A 4 → → → → → → → → ↓ ↓ ↓ ↓ ↓ ↓
F 3 → → → → → → → ↓ ↓ ↓ ↓ ↓ ↓ ↓
T 2 → → → → → → ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓
S 1 → → → → → ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓
↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓
↑ 5 ↑ 5
P 4 P 4 → Up (Warp Yarn)
I 3 I 3
C 2 C 2 → Down (Weft Yarn)
K 1 K 1
S # 1 2 3 4 5 6 7 8 9 10 S 1 2 3 4 5 6 7 8 9 10
Note: Drawing In Instruction of Design-B Is Same as Design-A
Drawing-In Instruction
And So On
Weave Plan
Shafts→
Lifting Plan
Ends→
Created By M@SUM
Drafting Plan
Design-A: 3/1 Right Hand Twill
(Based On 3/2 Right hand Twill)
Design-B: 3/2 Vertical Herringbone
Ends→
Weave Plan
Shafts→
Lifting Plan
Drafting Plan

↑ 6 → → → → → → → → → →
S 5 → → → → → → → → → ↓
H 4 → → → → → → → → ↓ ↓
A 3 → → → → → → → ↓ ↓ ↓
F 2 → → → → → → ↓ ↓ ↓ ↓
Ts 1 → → → → → ↓ ↓ ↓ ↓ ↓
↓ ↓ ↓ ↓ ↓ ↓
12 12
11 11
10 10
9 9
8 8
7 7
6 6 → Up (Warp Yarn)
↑ 5 ↑ 5
P 4 P 4 → Down (Weft Yarn)
I 3 I 3
C 2 C 2
K 1 K 1
S # 1 2 3 4 5 6 7 8 9 10 11 12 S 1 2 3 4 5 6
Shafts 1 2 3 4 5 6
12 → 1 2 5 6
E * 1 2 3 4 5 6 11 → 1 4 5 6
N 11 10 9 8 7 12 10 → 3 4 5 6
D 9 → 2 3 4 5
S * 13 14 15 16 17 18 8 → 1 2 3 4
23 22 21 20 19 24 7 → 1 2 3 6
To 6 → 1 2 3 4
Be * 25 26 27 28 29 30 5 → 2 3 4 5
35 34 33 32 31 36 4 → 3 4 5 6
D 3 → 1 4 5 6
R * 37 38 39 40 41 42 2 → 1 2 5 6
AW 47 46 45 44 43 48 1 → 1 2 3 6
N
Created By M@SUM
And So On
Drawing-In Instruction
Shaft To Be LiftedPicks
Design-C: 3/3 Dimond
Drafting Plan
Ends→ Shafts→
Weave Plan Lifting Plan
The drawing-in instruction of these designs are also shown.
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The fault- wrong drawing-in occurs when the warp ends are drawn in wrong
order. For example let us illustrate design-A.
Here the repeat consists of 4 ends; that
should have to be drawn in four separate
heald shaft serial wise.
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Now if 19 no. warp; that should have to be
drawn through the heald eye of 3 no. heald
shaft is drawn through the heald eye of 1 or 2
or 4 no. heald shaft; then it should result in
wrong drawing.
As a result of wrong drawing the
corresponding end/ends are being woven in
wrong order & therefore faulty fabric is
produced.
Shafts→ 1 2 3 4
* 1 2 3 4
* 5 6 7 8
* 9 10 11 12
* 13 14 15 16
* 17 18 19 20
* 21 22 23 24
* 25 26 27 28
* 29 30 31 32
EndsToBeDrawn↑
And So On
Causes:
■ Incorrect order of drawing.
Remedy:
■ Drawing-in should be done very carefully.
■ Vigilance during mounting a new beam should be strict enough so that
wrong drawing-in can be detected & rectified immediate after running a new
beam & it doesn’t occurs any more after mending once.
4. Wrong Denting:

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The fault in a woven fabric that is caused due to the incorrect order of
enting of warp ends through the reed is called wrong denting.d
For example; let us consider a fabric is running with 71 EPI in a loom
having reed count 698 DM (DM→ Dents Per Miter). So 4 ends should be
drawn through each dent of the reed. Now if more or less then 4 ends are
rawn in any one of the dent; then it will result in wrong denting.d
Due to wrong denting line mark is produced in the fabric.
Causes:
■ Incorrect order of denting of warp ends through the reed during denting.
■ Incorrect order of denting of warp ends through the reed after breakage of
warp end.
Remedy:
■ Denting should be done very carefully.
■ Vigilance during mounting a new beam should be strict enough; so that
wrong denting can be detected & rectified immediate after running a new
beam.
■ After warp breakage if it needs to draw the broken end through the dent
of the reed; then this task should be done very carefully & the fabric should
be checked properly immediate after re-starting the loom for detecting the
existence of wrong denting.
5. Balls:
When small globular fibrous substances appear on the fabric surface (either
on face or on back or on bath side); then it is called balls.
Balls are the result of entanglement of fibrous substances on the yarn
surface. Usually all kinds of yarns contain more or less hairiness. When
those protruding fibers are being aborated by the loom parts like drop-wires,
heald eyes & dents; the yarn become more hairy. When some hairy warp
ends passes together through a single dent; the protruding loose fiber on
their surface tends to be entangled together. In this way balls are generated.
Existence of fibrous dust in the weaving floor emphasizes the formation of
balls.

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Causes:
■ Excessive hairiness in the warp.
■ Drawing more no. of ends then recommended through the dents of the
eed.r
■ Rough surface of drop-wires, heald eyes & dents of the reed.
■ Excessive fibrous dust in the weaving floor.
■ Less cleaning effort of looms.
Remedy:
■ Better quality warp (less hairy) should be used.
■ Excessive no. of ends shouldn’t be drawn through the dents of the reed.
■ Rough surfaced drop-wires, heald eyes & dents of the reed (if any) should
be changed.
■ Standard temperature & RH% should be maintained for reducing floating
dust.
■ The weavers beam (mounted on the loom) & the yarn sheet exposed from
the weavers beam to the weaving zone should be cleaned after a regular
interval by directing compressed air.
b) Faults Related With Weft:
6. Snarls:
Snarl is the result of defective pick insertion. When a weft yarn can’t pass
through the shed smoothly & obstacles in its path then snarl is formed. Due
to snarl formation the fabric surface take a rough look & rough hand fill at
the place where snarl has formed.
Causes:
■ Defective picking arrangement.

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■ Incorrect setting of picking arrangement.
■ Incorrect air pressure in air-jet looms.
■ Polyester or any other synthetic yarn show higher tendency of snarl
ormation.f
■ When cotton-lycra plied yarn is used as weft yarn in air-jet looms, then
after each loom stoppage if the weft yarn end doesn’t release from nozzle
during re-starting loom; then there is too much higher possibility of snarl
formation.
Remedy:
■ Faultless picking arrangement should be used.
■ Accurate setting of picking arrangement should be confirmed.
■ In air-jet looms air pressure should be adjusted accurately depending on
the yarn type (cotton/synthetic, single ply/multiple ply, lycra etc.).
■ During using polyester or any other synthetic yarn, extra vigilance should
be imposed.
■ When cotton-lycra plied yarn is used as weft yarn in air-jet looms, after
each loom stoppage the weft yarn end must be released from nozzle during
re-starting loom.
7. Broken Pick:
If any weft yarn doesn’t reach to the other side of the selvedge; rather it
remains at any place between two selvedges of both sides then this fault is
termed as broken pick.
Due to broken pick a mark is found across the width of the fabric that is
visualized in that place where the weft yarn is missing.
Causes:
■ In case of air jet looms this problem is created due to excess air pressure
or fluctuating air pressure. Excessive air pressure cause the weft yarn to be
torn & thus broken pick is inserted.
■ In any kind of loom broken pick can be generated due to defective pick
nsertion arrangement.i

■ Incorrect setting of pick insertion arrangement is another vital cause of
roken pickb
■ Insufficient strength of weft yarn is responsible for broken pick.
■ Malfunctioning of the weft stop motion is another vital cause of broken
pick. All modern looms are provided with electric weft stop motion. This
motion is provided with a sensor that is fitted to the opposite side from the
picking side.
This sensor bears 3 LED at its sensing head.
The setting is done in such way that each weft
yarn passes through beneath of those LED.
When the sensor finds that a pick has already
been inserted but it has not reaches to the Led;
then the sensor will send a signal to the
processor of the loom that will stop the
machine immediately.
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According to the described mechanism it seems
that there is no possibility of insertion of
broken pick until the sensor works on properly.
Figure-1
The Sensing Head
Courtesy : Ha-Meem Denim Ltd.
But sometimes the LED in the sensing head
becomes covered with dust; as a result the
sensor fails to detect broken picks.
If the sensor bears any electrical or mechanical fault; that will also fail to
detect broken picks, but in this case any corresponding signal lamp or the
display of the loom will provide message about the fault of sensor.
Remedy:
■ In case of air jet loom pressure setting should be adjusted accurately.
■ Pick insertion arrangement should be checked regularly & defective pick
insertion arrangement (if any) should be replaced.
■ Accurate setting of pick insertion arrangement should be confirmed.
■ Bad weft packages should be avoided.
■ Functioning & setting of weft stop sensor should be checked regularly.
■ The sensing head of the weft stop sensor should be cleaned by soft cloth
for several times within a shift for preventing it’s malfunctioning for dust.

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■ Atmospheric cleanliness should be ensured for preventing malfunctioning
of pick insertion arrangements & weft stop sensors. Standard atmospheric
condition (temperature & RH %) should be maintained in the weaving floor.
8. Miss Pick:
When a pick doesn’t insert but the loom continues to run with a pick
missing; then faulty fabric is being produced. This fault is termed as miss
pick.
Due to miss pick; a horizontal mark is visualized across the full width of the
fabric. The mark is obtained in that place where the pick had missed.
Causes:
■ Defective pick insertion arrangement.
■ Incorrect setting of pick insertion arrangement.
■ Malfunctioning of the weft stop motion due to dust or electrical or
mechanical problem.
Remedy:
■ Pick insertion arrangement should be checked regularly & defective pick
nsertion arrangement (if any) should be replaced.i
■ Accurate setting of pick insertion arrangement should be confirmed.
■ Functioning & setting of weft stop sensor should be checked regularly.
■ The sensing head of the weft stop sensor should be cleaned by soft cloth
for several times within a shift for preventing it’s malfunctioning for dust.
■ Atmospheric cleanliness should be ensured for preventing malfunctioning
of pick insertion arrangements & weft stop sensors. Standard atmospheric
condition (temperature & RH %) should be maintained in the weaving floor.
9. Weft Yarn Fault:
In fact weft yarn fault is not a weaving fault. This fault is obtained due to
bad quality of weft yarn. Darker & lighter shaded bands obtained across the

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full width of the fabric either in periodic (most common) or non periodic
order. The shaded bands are prominent on that side on which the weft yarn is
prominent. For example, in case of 3/1 right hand twill fabric the shaded
bands will be prominent on technical back side of the fabric. But in case of
1/1 plain fabric the shaded bands will be prominent on both sides of the
fabric.
Causes:
■ Bad weft supply package.
Remedy:
■ Bad weft supply package should be avoided.
■ Vigilance should be strict enough; so that weft yarn fault can be detected
rectified immediately when it starts to occur.&
■ During & after feeding new weft supply package; fabric should be
checked properly for detecting weft yarn fault (if any).
c) Faults Related With Loom Operation:
10. Starting Mark:
Starting mark is a fabric fault that is created due to loom stoppage. When a
running loom stops for any reason; then after re-starting the loom a
horizontal mark across the fabric width is visualized. This is called starting
mark.
Basic reason of formation of starting mark:
When a loom continues to run then both the warp ends & the weft yarn
remain in motion. Sudden stoppage of loom will break that motion & due to
he inertia the fell of the cloth will not reach at the correct position.t
Starting mark is created when fell of the cloth doesn’t remain at the correct
position; rather it stays slightly rearer position. As the fell of the cloth stay
rearer then its accurate position; so the newly inserted weft doesn’t mash
with the cloth fell properly, rather a slight gap exist between the cloth fell &
the newly inserted pick. As a result starting mark is created.

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Basic mechanism for preventing formation of starting mark:
Modern looms are provided with automatic anti starting mark procedure.
The purpose of this procedure is to prevent the formation of starting mark.
The basic mechanism for preventing starting mark is different for different
rands of looms. Here I am giving the description of two procedures.b
■ In PICANOL looms after each loom stoppage the take-up roller along
with the fabric moves in opposite direction. So, the fell of the cloth moves
slightly backward (towards the reed). Therefore after re-starting the loom,
the reed will strike the newly inserted pick at a comparatively high force
then that of the regular force. As a result the gap between the cloth-fell & the
ewly inserted pick (if any) should be removed.n
■ In TSUDAKAMA looms the mechanism of automatic anti starting mark
procedure is based on reed motion. In this loom after each loom stoppage
when the loom is re-started the reed strike is done at a higher force then
regular beat-up. This higher beat-up force will remove the gap between the
cloth-fell & the newly inserted pick (if any).
Causes:
■ Incorrect setting of reed in its profile.
■ Incorrect setting of back-rest.
■ Incorrect tension on the warp.
■ After loom stoppage for weft stop, it is recommended to remove one pick
before re-starting the loom. But if more then one pick is removed; then
starting mark can be obtained.
■ Excessive jerking in the weaving zone during stoppage & starting a loom
due to mechanical problem.
■ In case of looms provided with automatic anti starting mark procedure
excessive delay for re-starting a loom after stoppage will result in formation
of starting mark.
Remedy:
■ Setting of reed should be accurate.

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■ Setting of back-rest should be accurate depending on warp yarn count &
eave.w
■ Tension on the warp should be accurately set depending on the warp yarn
ount.c
■ Any kind of undue jerking should be avoided by proper setting & regular
servicing of loom.
■ In case of loom stoppage due to weft stop only one pick should be
removed.
■ In case of looms provided with automatic anti starting mark procedure;
the loom should be re-started as early as possible after each stoppage.
11. Temple Mark:
Temple mark is one of the most typical faults in woven fabric. It comes
vertically in the fabric beneath within the range of the temple width.
In case of fabrics produced from dyed warp, a white mark is visualized
across the length of fabric due to temple mark. In case of fabrics produced
from grey warp, the problem associated with temple mark is being
visualized after dyeing. In this case shade variation occurs across the area
affected by temple mark.
Causes:
■ Defective temple, e.g. blunt temple ring, jammed temple ring or roller.
■ Incorrect setting of temple support.
■ Incorrect setting of temple.
Remedy:
■ If temple is defected; that should be changed.
■ The setting of temple support should be correct.
■ The setting of temple should be correct.

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■ Some times temple mark comes even after taking all the described
actions. In that case; the temple should be dis-assembled & some of the
temple ring should be removed from it. The temple rings should be removed
until that portion where the temple mark had generated. Then the temple
should be re-assembled again.
12. Line Mark:
Line mark is a fabric fault for which vertical mark appears in fabric. It may
appears in one place or more than one places at a time.
Causes:
■ Improper arrangement of warp ends with different counts is one of the
most vital reasons of line mark. Sometimes there may be more than one
count in a single beam. For example let us consider the following
construction:
(7Oe
+9 Oe
+12 Oe
) x 16-L40D/66 x 46 Oe→ Open End.
[1:2:2] 16L-40D→ 16 Lycra-40 Denier.
Here the warp contains 3 types of yarns having different counts. Those are
7Oe
, 9 Oe
& 12 Oe
. Their corresponding ratio is 1:2:2. That means throughout
the warp sheet there should be 1 end of7Oe
, 2 ends of 9 Oe
& 2 ends of 12 Oe
.
This arrangement of warp must be maintained throughout the warp sheet.
Where this arrangement will be broken; there line mark will be obtained.
■ Defective loom parts e.g.-drop-wires, heald eyes & dents of the reed.
■ Wrong denting.
■ Existence of foreign count in the weavers beam. For example, let a
weavers beam contains warp of 30R
(Ne). Now if one single end of 40R
(Ne)
or 16R
(Ne) or any other count except 30R
(Ne) exist in that beam; then the
fabric produced from that beam will bear a line mark in the place where the
yarn of foreign count [40R
(Ne) or 16R
(Ne) or any other count except 30R
(Ne)] exists.
Remedy:

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■ In case of beams that contains warp ends with different counts; the ends
should be properly arranged by maintaining the correct ratio. Proper
rrangement of warps can be achieved by leasing.a
■ Defective loom parts should be replaced (if any).
■ Wrong denting should be avoided.
■ Foreign count should be avoided. Foreign count in the beam is the result
of defective warping. So warping should be done carefully. But if foreign
count exist in the beam; then it should be detected & replaced by the reserve
end of accurate count.
13. Crease Mark:
Most of the modern looms are provided with batchers; on which the
produced fabric is being rolled. It is expected that a fabric roll should be
cylindrical in shape. But sometimes rolls are found to be slightly funnel
shaped (convex on one side of the roll & concave on other side of the roll).
Due to this unwanted shape, fabric tends to be curled on the concave edge.
When any portion of fabric is being curled that portion is being warped with
other layers of fabric. So eventually the curled portion has to withstand huge
pressure as the roll becomes larger in size. As a result crease mark is
generated on the curled portion of the fabric.
Causes:
■ Incorrect shape of roll on the batcher when it is formed.
■ Improper synchronization between batcher speed & take-up roller speed.
■ Loose or imbalanced tension on both edge & centre on the fabric that
exists between batcher & take-up roller.
Remedy:
■ Shape of roll on the batcher should be accurate cylindrical.
■ Batcher speed & take-up roller speed should be properly synchronized.
■ Tension on the fabric that exists between batcher & take-up roller should
be sufficiently balanced on both edge & centre. The fabric roll should be
formed under sufficient high tension.

d) Faults Due To Poor Vigilance:
14. Weft Yarn Count Mistake:
Sometimes wrong count of weft yarn is feed in the loom; that results weft
yarn count mistake. For example let a particular style requires 16/1 Ne as
weft yarn. Now if 12/1 Ne or 16/1 Oe yarn or any other yarn except 16/1 Ne
is used for that fabric; then the produced fabric will be faulty.
Causes:
■ Poor vigilance.
■ Careless duty of the operators & line in-charges.
Remedy:
■ Strict vigilance should be confirmed so that this fault can be detected &
ectified immediately when it occurs.r
■ Operators & line in-charges should be more careful.
15. Weft Yarn Ratio Mistake:
Some fabrics require 2 or more different types of yarn. The weft yarns may
contain different ratio. Two constructions of such fabrics are given bellow:
Ratio DistributionSl. No. Construction
Weft Yarn Ratio
12Oe
11. 30R
x (12Oe
+16Oe
)/66 x 45
(1:1) 16Oe
1
16Oe
12. 20R
x (16Oe
+300DPL
)/71 x 52
(1:3) 300DPL
3
R → Ring Yarn
Oe → Open end
DPL→ Denier
Polyester
During manufacturing fabrics containing different weft yarns with different
ratios; it should be confirmed that accurate ratio have set for each particular
ype of yarn.t
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For clear impression let us illustrate the 2nd
construction. Here there are 2
different weft yarns. 16Oe
should insert 1 pick & 300DPL
should insert 3
picks. If we select 1 pick for both type of yarn or the reverse ratio(16Oe
→3
icks 300p DPL
→1 pick) then faulty fabric will produced.
In case of modern looms which are provided with display; the weft ratio can
set & checked very easily by using the display. In case of semi-automatic
looms; the ratio is set manually.
Causes:
■ Poor vigilance.
Remedy:
rectified immediately when it occurs.
16. Unwanted Slub In Weft:
If any fabric doesn’t require slub yarn as weft yarn; but slub yarn is inserted
as weft yarn, then the fault is termed as unwanted slub in weft.
Causes:
■ Faulty weft package that contains unwanted slub.
■ Poor vigilance.
Remedy:
■ Faulty weft package should be avoided.
17. Slub Miss In Weft:
If any fabric requires slub yarn as weft yarn; but yarn without slub is
inserted as weft yarn, then the fault is termed as slub miss in weft.

Ha-Meem Denim Ltd.
Page 21 of 21
Causes:
■ Poor vigilance.
Remedy:
e) Miscellaneous Faults:
18. Gout:
Gout is not a frequently occurring fabric fault it occurs seldom. If any small
hard but pliable material e.g.- small pitch of wood or hard paper or polythine
is being woven in the fabric, then when that material is taken out from
fabric; a hole appears in that place where the foreign material existed. This
fault is known as gout.
Causes:
■ Falling of any small hard but pliable material in the weaving zone.
■ Floating dust in the weaving floor.
Remedy:
■ Floor cleanliness should be strengthen.
■ Standard temperature & RH% should be maintained for reducing floating
dust.
These are the faults that frequently occur in weaving.
…………… ■ ……………

Fabric Faults & Remedy-Updated

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