DYEING FAULTS Many faults that appear in fabrics and yarns after dyeing are not all related

to dyeing. Many of these faults can be traced back to prior production processes. It is important therefore when assessing a fault to try to ascertain the root cause. Careful consideration of the possible cause of the fault will enable suitable corrective action to be taken to ensure that the same faults do not re-occur. Whilst the following list is not exhaustive it highlights some of the problems that dyers face on a daily basis.

PIECE DYEING
Fabric preparation Fabric that has had a poor preparation history will invariable give problems during dyeing that may not be readily apparent as dyeing faults. Quality control procedures should be in place to ensure that preparation is correct, particularly in the case of fabric to be dyed continuously.

CONTINUOUS DYEING FAULTS Side to side variation Uneven heat setting, where one side of the fabric reaches a higher temperature than the other side. Uneven padder pressures causing a greater pick up on one side to the other. Poor preparation can also result in uneven dyeing due to poor wet ability and the presence of size that has not been removed. End to end Variation Variation in concentrations of chemicals or dye in dye trough during padding. Variation in temperature or concentrations of chemicals in developing, rinsing, soaping baths, particularly for vat dyes. Temperature variation during heat setting Drying out after cold pad batch dyeing Poor preparation (unlevel bleaching or scouring) Resist Spots These show as areas where the dyestuff has not taken to the fabric Condensation drips from roof Marks or contamination on padder bowls Fabric wet before dyeing Undissolved chemicals Poor preparation Poor preparation

Resist marks due to water spotting on the fabric prior to padding with dyestuff.

Uneven streaks Insufficient dye or chemical in padding troughs Poor preparation Incorrect settings during oxidizing, developing or similar Pad Bowl damage or incorrect settings Dye stains Badly dissolved dye or chemicals Poor machine cleaning

Example of dye specks on cotton fabric

BATCH DYEING FAULTS

JETS AND WINCHES Dye creases or Running lines Incorrect pump or creel settings Incorrect loading Over loading or under loading machine Incorrect liquor ratio Inadequate heat setting Fabric unsuitable for rope dyeing

Note the presence of streaky lines on the fabric, due to overloading of the machine.

Crows Feet Heating or cooling too fast Incorrect fabric or liquor circulation Chafe or scuff marks Incorrect pump or creel settings Incorrect loading Over loading or under loading machine Incorrect liquor ratio Fabric tangles during dyeing

Uneven dye Incorrect choice of dyes or auxiliaries Incorrect machine settings causing poor circulation of either liquor or fabric. Incorrect rate of heating Insufficient time at final temperature Incorrect pump or creel settings Incorrect loading Over loading or under loading machine Incorrect liquor ratio

Dye specks or spots Poor dissolving or dispersing of dyes Poor choice of dyeing auxiliaries Poor machine maintenance and cleaning see attached example of the inside of a heat exchanger that has not been cleaned. Precipitation of oligomer behind the jet nozzle.

The effect of poor machine cleaning note the build-up of dyes and chemicals in the heat exchanger of a jet dyeing machine

JIG DYEING

Ending usually caused by poor dyestuff combination Listing often caused by temperature variations across the jigger. Dye spots, incorrect preparation of dyes and chemicals.

PACKAGE DYEING (YARN) Colour variation from the inside to the outside of the yarn package Incorrectly wound package (uneven tension, too much tension, wrong cross over angles, Package too large Spindle too dense due to over pressing prior to dyeing Pump pressure too low or too high Density of pressed packages too high Lighter areas of yarn Air trapped within package Damaged yarn Pump pressure too high Poorly wound package Manual handling errors Excessive processing