This document discusses common faults that occur in yarn dyeing and woven fabric dyeing processes. For yarn dyeing, the main faults discussed are package unlevelness, package to package shade variation, color spots, ring marks, and dirt marks. The causes of each fault are explained. For woven fabric dyeing, faults like white spots, color spots, crease marks, long stripes, uneven shade, running shade, and listing effects are discussed along with their typical causes. The document also mentions knit dyeing faults such as uneven dyeing, shade variation, crease marks, dye spots, soda spots, and holes. Finally, the document provides links to the author's Facebook pages on textile manufacturing technologies and

1. Southeast University
KNIT
DYEING
YARN
DYEING
WOVEN
DYEING

2. Prepared By : Mazadul Hasan sheshir
ID: 2010000400008
13th
Batch (session 2009-2013)
Department : Wet Processing Technology
Email: mazadulhasan@yahoo.com
Blog : www. Textilelab.blogspot.com (visit)
Southeast University
Department Of Textile Engineering
I/A 251,252 Tejgaon Dhaka Bangladesh
Prepared By :

3. Faults in Dyeing SectorFaults in Dyeing Sector

4. Yarn Dyeing Faults
1. Package un-level
2. Package to package shade
variation
3. Color spot
4. Ring mark
5. Dirt mark
Yarn
Dyein
g
Fault

5. 1. Package Unlevel
Causes:
a. Tension variation while soft winding of the
package
b. Lot mixing of yarns in the same package
c. Different counts of yarns in the same
package
d. Pressure variation in the machine vessel
e. Improper pretreatment of the yarn
f. Improper quality of the dyes and chemicals
g. Improper acid treatment after scouring and
bleaching

6. 2. Package to Package shade variation
Causes:
a. Improper setting of yarn packages in the machine
b. Lot mixing of the packages
c. Count variation of packages
Causes:
a. Improper setting of yarn packages in the machine
b. Lot mixing of the packages
c. Count variation of packages
Packag
e
Unlevel

7. 3. Color Spot
Causes:
a. Floating of dye particles in the air
b. Improper per-oxide killing
c. Hardness of water
d. Improper mixing of dyestuffs
Packag
e
Unlevel
P 2 P
shade
variatio
n

8. 5. Ring Mark
Causes:
a. Improper drying of the packages
b. Improper peroxide killing
4. Dirt Mark
Causes:
a. Dirty handling of the packages
b. Presence of dust in the air
Figure: Dirt mark
Packag
e
Unlevel
P 2 P
shade
variatio
n
Colo
r
Spot

9. Woven Dyeing Faults
1. White spot
2. Color spot
3. Bug spot
4. Water mark
5. Crease mark
6. Long stripe
7. Uneven shade
8. Running shade
9. Listing effect
10. Dirty mark
11. Oil spot
12. Stop mark
Woven
Dyeing Fault
Woven
Dyeing Fault
11
22
33
44
55
66
77
88
99
1010
1111
1212

10. Causes:
a. Foreign particles present on fabric before dyeing
b. Foreign particles present in the solution
c. Hairiness present in fabric from brushing
1. White Spot
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11. 2. Color Spot
Causes:
1. Dyes & chemicals factors:
a. Poor Dispersion or Solubility Properties
b. Unstable chemicals
c. Silicones in the dye bath
d. Alkali residues in the goods
e. Presence of iron
2. Improper Washing
3. Operator negligence
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12. 3. Crease Mark
Causes:
a.Lack of balance in construction of the fabric
b.Pressure of padder roller
c.Direct Heating or Shock cooling
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13. 4. Long Stripe
Causes:
a. Winding of yarn in padder roller
b. Improper pressure during brushing
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14. 5. Uneven Shade
Causes:
a. Improper scouring
b. Improper bleaching
c. Improper mercerization
d. Low solubility of dyes & chemicals
e. Negligence of operators to solubilize dyes and
chemicals
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15. 6. Running Shade
Causes:
a. Change in pick-up percentage along the length of
the fabric
b. Improper fabric Speed.
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16. 7. Listing Effect
Causes:
a. Improper padder pressure in different zones of padder roller (left, middle & right zone).
b. Worn out squeeze roller.
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17. 8. Dirt Spot 9. Oil spot
Cause:
Oil dropped on the fabric
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Causes:
Presence of Dirt in the air
Dirty handling of the fabric

18. 12. Stop mark
Cause:
Stopping of machine unexpectedly during processing.
Figure: Water Mark
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1
0
1
1
1
2
11. Bug Spot
Causes:
1. Insect present in any bath
(i.e. dye bath, chemical bath, washing bath)
2. Falling of insects on the fabric during dyeing.
10. Water Mark
Cause:
Water is dropped on the fabric after final drying.

19. 1. Uneven Dyeing.
2. Shade variation.
i) Roll to roll shade variation.
ii) Batch to batch shade variation.
iii) Continuous shade variation in a roll
(Running shade/Tailing effect/Ending
effect)
iv) Side center side shade
v) Side to side shade.
3. Crease mark.
4. Dye spots.
5. Soda spots.
6. Hole
Knit Dyeing Faults

20. 1. Uneven Dyeing
Causes:
i) If uneven pretreatment is done, absorbency and whiteness of fabric will be different at different
places and consequently uneven dyeing will occurred.
ii) Very rapid addition of dyes and chemicals.
iii) Lack of controlling dyeing machine like-
- Machine speed.
- Temperature of the process.
- Dosing time.
- Circulation pump and reel speed.
- Plaiting device.
- M:L ratio.
- Improper washing after dyeing.

21. Causes:
- Machine over-loading.
- Running at lower nozzle pressure
- High bath draining temperature
- Improper cycle time
- Improper length of rope
2. Shade Variation
2.1. Roll to roll shade variation
Causes:
i) Not equal rope length in each chamber. Then cycle time will vary if reel speed will same and shade variation
occur.
ii) Not equal flow speed in each nozzle. Then cycle time will vary if length of each roll will same and shade variation
occur.
2.2. Batch to Batch shade variation
Causes:
i) Different batches are pretreated in different machines.
ii) Fabric of different batches has different dye affinity.
iii) Liquor ratio, cycle time, dye lot, chemicals, dyeing procedure, temperature are different for each batch.
iv) Low quality water especially PH, hardness and sodium carbonate content.
2.3 Running shade

22. Causes:
- More cycle time, more time fabric will be in folded condition increase tendency to crease mark
formation.
- Faulty plaiting device.
- Variation of heating & cooling rate.
- Improper fabric movement.
- For 100% cotton, if GSM>180, unbalanced structure, presence of lycra, not properly heat set increase
the tendency to crease mark formation.

23. 4. Dye Spot
Causes:
i.Operator negligence
ii.Dye bath hardness
iii.Improper Agitation of dyestuff
iv.Dye molecule deposition on the fabric

24. Causes:
1.Soaping start before wash
2.CaCO3 or MgCO3 in soaping bath.

25. 6. Hole6. Hole
Causes:
1. Dye bath water hardness.
2. Deposition of ferrous or ferric ion on the
fabric surface
3. Defective plaiting device of the machine.

26. Problem of dyeing
a. Problem of shade matching
Causes:
1. Dye factor
2. Process factor
3. Machine factor
4. Man factor
b. Fastness problem
Properties of Dyes & Chemicals affect fastness.
c. Hand feel problem

28. 1. Yarn Manufacturing Technology
Link : http://www.facebook.com/pages/Yarn-Manufacturing-Technology/485014954866808
2. Fabric Manufacturing Technology
Link : http://www.facebook.com/pages/Fabric-Manufacturing-Technology/459520217425605
3. Garments Manufacturing Technology
Link : http://www.facebook.com/pages/Garments-Manufacturing-Technology/472364799463126
3. Wet processing Technology
Link : http://www.facebook.com/pages/Wet-Processing-Technology-Dyeing-/468645219825404
4. Fashion-Design-and-Technology
Link : http://www.facebook.com/pages/Fashion-Design-and-Technology/587655294583875?ref=ts&fref=ts
My Facebook Textile related Pages
http://www.textilelab.blogspot.com (Visit )