Reasons and solutions for problems with yarn-dyed fabrics in the production process


1. Weaving point

There are regular or irregular weaving defects in the warp or weft on the fabric .
The main reason:

1 The strength of the yarn is not enough.
2 Yarn sizing bad (light or heavy).
3 Poor weaving equipment (when the weaving equipment is faulty, it will cause yarn breakage and other problems).
4 The lower fabric was not repaired completely.
5 The acceptance of finished products is not careful.

Solution: Strengthen repairs or make up.


2. Latitude/latitude arc (including size grid)

For fabric weaving and knitted fabrics, 2% weft/latitude arcs, and all corduroy fabrics with more than 3% skew are not allowed as first-class products .
The main reason:
1 Poor weaving equipment (when the weaving equipment is faulty, it will cause more shutdowns, causing weft/latitude arcs)
2 Bad finishing equipment (mainly refers to weft/latitude arc caused by poor finishing equipment).
3 Bad finishing (the weft/latitude arc caused by the operator's irresponsibility at the time of finishing).
Solution: Intensify repairs and rearrangements (instantiation).


3. When the shrinkage rate of the shrinkage rate of large fabrics exceeds the specified value, it cannot be set as the first grade. Different fabrics will have different ranges.
The main reason:
1 Bad finishing.
2 Defective pre-shrinking equipment.
Solution: Re-shrink again (to within the specified shrinkage rate) / fabric shrunk and so on.


4. The feel did not match the standard.

The feel of the fabric finished product and the feel of the standard sample were inconsistent and there were significant differences.
The main reason:
1 Bad finishing.
2 The raw material is incorrect.
3 The production process is incorrect.
Solution: Refresh/reproduction.


5. The color fastness of fabrics with poor fastness (dyed fabrics and dyed fabrics) cannot be consistent with the requirements.
The main reason:
1 Bad dyeing process.
2 Bad dyeing materials.
3 Bad finishing.
4 The operation is poor. (This is especially noticeable when the paint is scratched/dyeing)
Remedy: Re-fix/re-produce fabrics/re-stain (dyed fabrics can)/repair (paint-scrape/paint-stained fabrics can be used).


6. The fabric style cannot be consistent with the standard sample .

There is a clear gap between the style of the fabric and the standard (bamboo style/segment style/thickness, etc.).
The main reason:
1 Incorrect raw material (slub yarn incorrect / yarn incorrect)
2 The production process is incorrect (the dyeing process is not correct/the arrangement of slub yarns or yarn dyes is not correct)
3 After the finishing process is not correct (when the raw materials and the organization are correct, the correct finishing process will affect the fabric style)

Solution:
1 Reproduction of fabrics.
2 Redo the finishing.


The avoidance method for all the above issues:
1 Treat each order seriously (with responsibility).
2 The raw materials of the organization must be correct.
3 The production process must be correct.
4 Urge operators to be careful when operating.


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