This document discusses denim fabric and faults in rope dyeing. It begins with an introduction to denim, its properties and classifications. It then describes the rope dyeing process and compares it to slasher dyeing. The document identifies common faults in various textile processes like warping, dyeing, sizing, and weaving. For each fault, it provides the potential causes and recommended remedies. Diagrams are included to illustrate some example faults like bent picks or tight ends. In conclusion, the document expresses gratitude for learning about denim dyeing processes.

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