e-ISSN: 2582-5208

International Research Journal of Modernization in Engineering Technology and Science

Volume:03/Issue:04/April-2021 Impact Factor- 5.354 www.irjmets.com

IDENTIFICATION OF DIFFERENT TYPES OF DYEING FAULT, CAUSES AND

CONTROLLING METHOD FOR QUALITY AND PRODUCTIVITY
IMPROVEMENT
Md. Mazharul Islam*1
*1Student, Department of Textile Engineering, Primeasia University, Dhaka, Bangladesh.
ABSTRACT
Bangladesh is earning about 80% foreign currency from the textile sector by exporting the textile products
mainly to European region and USA. Nowadays this field has become very competitive. Quality of product is
very important to everyone. Buyers are very aware about the quality of product. To get quality product the
faults, which are occurring in different stages such as dyeing, printing and finishing, should be minimal. Due to
the faults, the production hampers and quality of the product degrades. Quality is the demands and when it
fulfils then it gives customer satisfaction and also enhances standard of a product. Whether the fault and quality
is maintained, also improve productivity. The goal of this research is to identify the dyeing faults for quality and
productivity improvement by controlling imperfection.
Keywords: Garments Washing, Garments Dyeing, Knit fabrics, Woven fabric, Dyeing faults, Causes and
Remedies, Quality Control, Productivity, Production, Cost Reduction.
I. INTRODUCTION
Dyeing is a process of treating fabric with dye liquors, which contain both dyestuffs & chemicals and fixing the
dyes subsequently on the fabric. During dyeing process, a lot of faulty dyed fabrics come out. Faults may arise
because of the followings
• Wrong pre-treatment procedures
• Insufficient agitation of dyeing liquor
• Wrong placement of fabric into the machine
• Improper working of dyeing machines
• Applying unsuitable dyeing recipes
• Pressure differences along the length of the squeeze rollers etc.
As dyeing faults incur losses we need to be conscious to produce fault free products hence facilitating cost
effective production.
II. EXPERIMENTAL
2.1 Methodology

Figure 1
2.2 Procedure
❖ First we have selected different textile industries & visited Dyeing sections (woven & knit),
❖ Then we have collected faulty dyed fabric samples.
❖ To confirm the proper causes & their remedies we have interviewed the related person and collected
information.

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International Research Journal of Modernization in Engineering Technology and Science
Volume:03/Issue:04/April-2021 Impact Factor- 5.354 www.irjmets.com
2.3 Poor Leveling or Uneven Dyeing

Figure 2
Probable Causes:
❖ Poor dye solubility
❖ Low dye diffusion
❖ High dye affinity
❖ Dyes poor migration
❖ Too much salt
❖ Rate of dyeing to high
❖ Rapid rate of rise of temperature
Recommended Solution:
❖ Use of dyes of good solubility
❖ Use of dyes of optimum affinity
❖ Use of dyes of good migration
❖ Optimum concentration of salt
❖ Optimum rate of dyeing
❖ Optimum rate of rise of temperature
2.4 Dye specks or sport

Figure 3
Probable Causes:
❖ Poor pretreatment
❖ Water contamination
❖ Contaminants in salt, alkali, etc.
❖ Insufficient dissolving of the dyestuff
❖ The flying about dye particles which cling on to fabric
❖ Improper cleaning of the dyeing machine after color change
Recommended Solution:
❖ Good pretreatment
❖ Water purification or use of sequesting agent
❖ Good quality control of commodity chemicals
❖ Usually it is possible to remove these spots by hot wash with soaping agent

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Volume:03/Issue:04/April-2021 Impact Factor- 5.354 www.irjmets.com
2.5 Crease Mark

Figure 4
Probable Causes:
❖ Over loading of the dyeing machine
❖ Dyeing at high temperature
❖ On synthetic fabrics it occurs because of the contraction caused by hot air and/hot water
❖ In dye bath, anti-creasing agent is not work perfectly
Recommended Solution:
❖ Can be removed from cotton goods by treating with crack inhibitors/cross-linking agent
❖ In mercerizing process
❖ Thermos fixation needed for synthetics
❖ Anti-creasing agent work with perfectly
2.6 Oil & Grease Spot

Figure 5
Probable Causes:
❖ During dyeing & finishing process sometimes oil & grease may fall on fabric which may cause oil &
grease spot on the dye fabric
❖ Due to careless transport of dyed or finished fabric
Recommended Solution:
❖ Must be careful about oil & grease during dyeing & finishing process
❖ Must be careful about the transportation of dyed or finished fabric
2.7 Needle hole

Figure 6

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Probable Causes:
❖ If yarn strength is less
❖ If needle is curve
❖ If mineral metal stay in fiber
❖ If broken needle is active on needle action
Recommended Solution:
❖ Sufficient yarn strength is necessary
❖ Proper pre-treatment is required
❖ Before starting needle action, needle should be checked
2.8 Piling

Figure 7
Probable Causes:
❖ Susceptible fiber origin (also in fiber blends)
❖ Inconsistence dimensional stability due to shrinkage
Recommended Solution:
❖ Select fibers carefully
❖ Use selected softeners
2.9 Unlevel

Figure 8
Probable Causes:
❖ Wrong placement of the fabric in machine
❖ Improper working of dyeing apparatus
❖ Applying unsuitable dyeing recipes
Recommended Solution:
❖ This type of faults can be dominated by either removing the dye or re-dyeing or re-wash the fabric into
dark shades like black or navy.
2.10 Physical Damage

Figure 9
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Probable Causes:
❖ Too long dyeing time
❖ Too high mechanical or hydraulic action
❖ Too high temperature
❖ High Drum RPM
Recommended Solution:
❖ Right first time dyeing
❖ Optimum hydraulic or mechanical action
❖ Optimum temperature
2.11 Water Spot

Figure 10
Probable Causes:
❖ Fixation with a few drops of water on specific are of dyed fabric
Recommended Solution:
❖ Need Proper fixation
2.12 Hairiness

Figure 11
Probable Causes:
❖ Carded yarn produces highly hairiness fabric
❖ Improper singeing
Recommended Solution:
❖ Use combed yarn
❖ Proper singeing
2.13 White Spot

Figure 12
Probable Causes:
❖ Due to dead fiber

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Recommended Solution:
❖ Remove dead fiber during spinning
2.14 Shading

Figure 13
Probable Causes:
❖ Fabric shade variation is the variation of shade or depth of color in same fabric roll.
Recommended Solution:
❖ Numbering of each single parts of garments should be accurate.
❖ Operator must check the garments number before sewing.
2.15 Trims shade not match with the body

Figure 14
Probable Causes:
❖ Different types of yarns used in fabric and trims.
❖ Dye lot is different for trims and body.
❖ Improper recipe setting for trims and fabric.
Recommended Solution:
❖ Same type of yarn, dye lot, recipe, nozzle pressure, uniform distribution to each nozzle etc.
❖ Should be used for both fabric and trims.
2.16 Running shade problem

Figure 15
Probable Causes:
❖ Machine loading is higher.
❖ Running at lower nozzle pressure.
❖ High bath draining temperature.

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Recommended Solution:
❖ Proper cycle time should be ensured.
❖ Nozzle pressure should be accurate.
❖ Bath draining temperature should be moderate.
2.17 Softener Mark
Probable Causes:
❖ If pH is not maintained
❖ Poor emulsification of softener applied
❖ Inferior quality of softener
Recommended Solution:
❖ Ensure that the softener is uniformly dissolved in the water
❖ Use the right softener and the correct procedure for the application.
❖ Maintain the correct ph.
2.18 Lycra Breakage

Figure 16
Probable Causes:
❖ During dry process getting stress out
❖ Use inappropriate size of silicon carbide paper for hand scraping
❖ Use improper ratio of chemical
❖ Temperature and wash time not control exactly
❖ When don’t wash by lycra protector
Recommended Solution:
❖ Before Wash garments/fabric treated by lycra protector
❖ During dyeing use lubricating agent
❖ During garments wash reduce machine RPM
❖ Properly Maintain wash time and chemical
III. SURVEY RESULT & ANALYSIS
Our survey time one month here, we show the Average survey result of three sectors (Garments Washing, Knit
Dyeing and Woven Dyeing)
Average Survey Result of Garments Washing per day:
Table 1
Defects Name Total Defect Per Day Defect %

shade light 126 1.13

shade dark 110 0.98
shade blue 75 0.7
Tin /Color More 23 0.21

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Volume:03/Issue:04/April-2021 Impact Factor- 5.354 www.irjmets.com
wash crease mark 16 0.14

wash uneven 12 0.11

line mark 5 0.04

color spot 12 0.11

Dirty spot 37 0.33

Bleach Spot 9 0.08

Oil Spot 5 0.04
Part shading 4 0.04

Total Defects 432

Total No. of Pieces 11183
Inspected
Defect Hundred per 3.86%
unit (DHU)

Washing Defect

shade light shade dark shade blue Tin /Color More

wash crease mark wash uneven line mark color spot
Dirty spot Bleach Spot Oil Spot Part shading

Figure 17
After 30 days survey we got average result per day 3.8%. We see in washing sector shading issue is a main
problem but sometimes during garments dyeing we facing lots of problem like uneven, crease mark, color spot
arise. That’s why when any problem arise we follow recommendation suggestion and try to minimize those
issue.
Average Survey Result of Woven Dyeing per day:
Table 2
Defects Name Total Dyeing Fault Fault %
Per Day
Color Spot 3 0.4
Running shade 4 0.5
Uneven Shade 2 0.3

Crease mark 2 0.3

Stop mark 1 0.1
White spot 1 0.1
Oil Spot 2 0.3

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Volume:03/Issue:04/April-2021 Impact Factor- 5.354 www.irjmets.com
Oil mark 2
0.3

Line mark 3 0.4

Water spot 1 0.1
Total Dyeing 20
Fault
Total Fabric 750 Meter
Inspected
Total Dyeing 2.67%
Fault %

Dyeing Fault of Woven Fabric

4% 14%
14%

11% 18%

11%
11%
3%
3%
11%

Color Spot Running shade Uneven Shade Crease mark Stop mark
White spot Oil Spot Oil mark Line mark Water spot

Figure 18
After 30 days survey we got average result per day Woven Dyeing Fault 2.67%. If we see the chart, we see that
running shade are most commonly problem in woven dyeing. Color spot and uneven dyeing are also found in
good percentage. White spot & Water Spot are less founded fault in woven dyeing. When any dyeing problem
arise, we follow the recommendation suggestion for solving this problem and reduce Dyeing Fault.
Average Survey Result of Knit Dyeing per day:
Table 3
Defects Name Total Dyeing Fault Fault %
Per Day
Dyeing spot 3 0.6
Soda spot 2 0.4
Uneven dyeing 3 0.6
Running shade 1 0.2
Chemical spot 2 0.4
Wrinkle mark 1 0.2
unwanted mark 2 0.4
Oil mark 1 0.2

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Softener mark 1 0.2
Shrinkage 0.5 0.1
Total Dyeing Fault 16.5

Total Fabric 500 kg

Inspected

Total Dyeing Fault 3.30%

%

Dyeing Fault of Knit Fabric

3% 19%
6%6%
12%
12%
6%
12% 18%
6%

Dyeing spot Soda spot Uneven dyeing Running shade

Chemical spot Wrinkle mark unwanted mark Oil mark
Softener mark Shrinkage

Figure 19
After 30 days survey we got average result per day Knit Dyeing Fault 3.30 %. From the pie chart, we shows that
the most commonly found dyeing spot, chemical spot. Shrinkage are less founded fault in knit dyeing. When any
dyeing problem arise, we follow the recommendation suggestion for solving this problem and reduce Dyeing
Fault.
IV. CONCLUSION
In this research work, we have acquired the ideas, principles & procedures involved with the dyeing faults,
their causes & remedies. For getting optimum production with desired quality, one should be aware of the
faults, which are occurring in different manufacturing stages. From this research work, we got different survey
result among Washing, Woven dyeing and knit dyeing. We hope our work will help to reduce fault and produce
quality product in this competitive market. This paper helped us to be conscious about the dyeing faults and to
take remedial actions accordingly.
V. REFERENCE
[1] P. S. Chinta and S. Dhar, Problems in Dyeing and Their Remedies, Research Gate, 2007.
[2] E. FEILMANN, Some Unsolved Dyeing Problems, Journal of the Society of Dyers and Colorists, 2008.
[3] Moin, C.J., and Mahabubuzzaman, A.K.M. 2009. Process for level dyeing of 100% cotton knit fabrics with
reactive dye. J. in-nov.dev. strategy 3(4): 01 08.
[4] Md. Moyinul Islam, Sakil Mahmud. Study on Different Types of Dyeing Faults, Causes and Remedies of Knit
Fabrics. IJET-IJENS Vol:15 No:02.
[5] Mohammad Abu Taher , Md. Mostafizur Rahman. Study on Different Types of Knitting Faults, Causes and
Remedies of Knit Fabric. SAP 2016, 5(6):119-131.
[6] http://web.b.ebscohost.com/abstract?direct=true&profile=ehost&scope=site&authtype=crawler&jrnl=13
003356&AN=74425718&h=niDowfP1lajbLOLo6PMbIUDDVsdojADLFnHRa9kHf7omC23uPpRBxn2vjFhRZ
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b1%2fh4DaIpFzmXd2HJH5PzUfcQ%3d%3d&crl=c&resultNs=AdminWebAuth&resultLocal=ErrCrlNotAut
h&crlhashurl=login.aspx%3fdirect%3dtrue%26profile%3dehost%26scope%3dsite%26authtype%3dcra
wler%26jrnl%3d13003356%26AN%3d74425718.
[7] http://www.garmentexporthouse.com/2013/12/what-is-shade-variation-in-fabrics.html.
[8] http://garmentspedia.blogspot.com/2015/11/garments-defects-stitching-in-garments.html.

Industries
[9] Norp Knit Industries Ltd. Gazipur, Bangladesh.
[10] NZ Textile Ltd. Dhaka, Bangladesh.
[11] Consumer Knitex Ltd. Mymensingh, Bangladesh.

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