The main endeavour of any business enterprise is to produce acceptable quality product at minimum cost. With the advent of new dyeing machines, advanced speciality chemicals and application of management technology, producing QUALITY FABRICS is possible by appropriate utilisation of technology & process control right from knitting to finishing. As far as processing is concerned, processing of tubular fabric is being done in softflow machines more and more even though processing in winches is also still being continued. Since knit goods are predominantly dyed using REACTIVE dyestuffs, problems related to reactive dyeing only are discussed. In overflows jets, there are four factors that should be adjusted when setting up a machine for process. These are 1. WATER LEVEL 2. WINCH SPEED 3. JET PRESSURE 4. NOZZLE SETTING (Depending on the machine) All these factors will influence the running of the machine & affect the quality of fabric dyed, even though appropriate chemicals & dyestuffs are used. The following are some of the common problems faced during the wet processing of knit goods, its causes and remedial measures.
PRE-TREATMENT
Problems
1. Entanglement of fabrics
Probable Causes
l Very less jet-pressure, over loading of
Remedial Measures
l Adjust the jet pressure, calculate
fabrics, causing fabric tube to Jam in front of the machine, making it difficult for the winch to lift and transport the fabric.
l Too high jet pressure also leads to
weight of the fabric to be loaded based on the rope length,diameter of the tube & gsm.
l Always load the fabric at warm
entanglement at the reel and accumulation of fabric at the rear side of the machine.
after adding Sandoclean PCJ/ LFD/HPJ Liq. For foams due to impurities (lubricants, wax), antifoam based on non-silicone chemicals are recommended, Antimussol HT2S Liq. dyeing and pretreatment.
used for knitting or due to surfacants / wetting agents that has more foaming properties. 2. Oil marks on fabrics
l If the fabric is stored for more than a week,
it may oxidise depending on the quality of knitting oil or lubricant used. The quantity of such oil/lubricant on the fabric can be more because of splashing of oil due to unexpected machiner y problems or due to irregularity of yarn.
l Improper house keeping and handling
by special scouring with 1.0-2.0% Sandoclean PC/PCJ Liq., 0.75 - 1.5% Imerol SR Liq. Boil, 30 min. at pH 9.0 followed by rinsing after neutralising.
l Lab pre-trials are required
of rolls.
3.
End-marks
Problems
4. Pin-hole damage
Probable Causes
l Presence of sharp metallic parts in some
Remedial Measures
l Check the presence of any sharp
bath.
l Presence of heavy metal ions
steam lines. Use Sirrix 2UDI in pretreatment, to ionise Fe ions present in grey cotton and keep in complexed form after their removal.
l Clean main water tanks / pipes. l To follow the following process for
Rinse Warm, 60C, 10 min Sandoclean LFD Liq. 0.25% Stabilizer SIFAM Liq. 0.25% Boil NaoH Flakes 1.0% 30 min H2O2 2.0-3.0% Hot wash 80C. 15 Min. Neutralise with Sirrix N Liq. 0.5%, 60C, 20 min 5. Uneven surface appearance particularly on interlock fabric
l This problem mainly occurs when the grey l Fabric may be singed to remove
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cotton quality is poor. Other possible causes are :l Too high mechanical stress on the fabric results in pilling or metal to fabric and fabric to fabric frictions.
action on the fabric, machine can be run at a compromising speed during scouring & washing. (i.e. running at optimum speed depending on machine type)
l Use of Lubricants like Imacol CG
because of bad running properties created, action of alkali & low cost solvent based wetting agents.
l Long duration of running due to
Liq.
reprocessing
gives best results without too much fluff. Process: Sandoclean PCJ Liq. 0.5g/l Sirrix 2UDI Liq. 2.0g/l 0.3g/l Imacol CG Liq. Then add Bactosol CA Liq 0.6-1% } 60C, 45min After this process, continue scouring in the same bath.
60C, 10 min
6.
structure of knit pattern is tight, the entrapped air cannot go out & results in balooning which in turn leads to entanglement.
near the joint of two tubes enables the air to escape. l The use of larger diameter nozzle will also minimize the problem. l Addition of deaerating & penetrating agent (Sandozin NA Liq.) can be added as a safety measure.
Problems
7. Poor absorbancy of fabrics after scouring / Peroxide boil
Probable Causes
l Presence of Ca & Mg salts on fabric and in
Remedial Measures
l Protonic pretreatment before
scouring gives an outstanding cleaning effect. Light weight fabrics: Sirrix 2UDI Liq. 1-2g/l Sandoclean PCJ Liq. 0.5g/l 60C, 30 min, Rinse Heavy weight fabrics: Sirrix YK Liq 2.0g/l Sandoclean LFD Liq. 0.5g/l 80C, 30 min, Rinse hot Use of Sandoclean PCJ Liq. is recommended as a wetting agent. The synergistic properties of the product helps to penetrate into the core of the fibre by eliminating fibre-liquid surface tension, and saponification of all impurities. So, fabrics obtain very good absorbancy.
l Ensure high temp. rinsing at 80C. l Addition of Sirrix 2UDI Liq. in
agents which have low alkali stability, and hence cannot assist the penetration of Caustic Soda for efficient saponification reaction. Because of poor detergency and dispersing effects, paraffin wax cannot be removed completely.
8.
a decomposition catalyst for H2O2. In a freely circulating bath new sources of iron oxides form, as a chain reaction of homolytic cleavage of H2O2 into hydroxide radicals which attacks cellulose to form oxycellulose.
Peroxide bleach bath or by one step combined protonic pretreatment & scouring. Sandoclean PCJ Liq. 0.5g/l Sirrix 2UDI Liq. 1g/l 20min Then continue peroxide bleach in the same bath. Addition of Stabilizer SIFAM Liq. also prevents the formation of atomic oxygen responsible for cellulose damage.
l To add Bactosol ARLI Liq. in the
60C,
9.
ment, residual peroxide will be left over on the fabric. If it is not removed completely, It may lead to the decomposition of some sensitive reactive dyes to non-homogeneous components, in a mixed shade dyeing.
neutralisation bath for eliminating H 2 O 2 in a biological way. Bactosol APN Liq. can be used in winch.
l Both the products promote quickly,
10.
linear dosing)
l Efficient neutralisation of the alkali
after mercerising.
l Damage of cellulose during the fast
transport through the jet nozzle. The damaged portion of the substrate is deeply dyed. (mainly on viscose)
bath with Imacol C2G Liq. alongwith Sandoclean PCJ Liq. ensuring proper piling & smooth running.
Problems
11. Whiteness variation
Probable Causes
l Presence of insoluble earth alkali on some
Remedial Measures
l To achieve the optimum consump-
tion of H2O2 a protonic pretreatment with Sirrix 2UDI Liq. before bleaching is recommended.
l Use 2.5 - 5.0 gpl Mercerol QW
12.
Uneven wetting during mercerising Inconsistency in basic whiteness after pretreatment Light coloured reserved portion on Cotton / Lycra fabrics
agent.
l Because of poor stabilization of H 2O 2
13.
bleaching
l Improper pretreatment & use of poor
14.
quality wetting agents which could not remove the mineral oil-content from the fabric completely.
should be heat set & bleached using Sandoclean PCJ Liq. as scouring & wetting agent, at pH 10.5.
OPTICAL BRIGHTENING
Problems
1. Poor whiteness
Probable Causes
l Some grey cotton carry a lot of hardness
Remedial Measures
l Give a protonic pretreatment
forming substances, which interfere in the bleaching reaction of Hydrogen Peroxide on cellulose.
l Overdosing of optical whiteners & drying
before Hydrogen Peroxide bleach using Sirrix 2UDI / YK Liq. Sandoclean PCJ Liq.
l Use optimum quantity of optical
whitener & controlled drying, preferably below 130C. Use acid stable OBA in case of neutralising like Leucophor BMF Liq. 2. Poor wash fastness of whites
l Improper choice of optical whitener. l Use Leucophor BA/BH Liq. as
3.
present in polyethylene bags as an antioxidant. If the fabric is in the neutral or alkaline side the yellowing reaction starts.
medium (pH 5.5 - 6.0) using Sirrix 2UDI Liq., and keep the fabric away from Nitrogen oxides. Use wrapping without BHT.
l Use Leucophor BMF which is
4.
Yellowing of whites if finished at acidic side as per Okotex requirement Aqueous extract of the fabric is alkaline
5.
at the end of finishing operation, it forms a buffer of sodium acetate at the liquidfabric interface and prevents the entry of further Acetic acid to the core of the fibre.
l Improper selection of optical brightening
of finish bath which can penetrate into the fibre to neutralise the core alkali, which is responsible for alkaline pH.
l Use Leucophor BFBI/BMF Liq.
6.
Tailing of white fabrics, when OBA is applied by padding application Yellow streaks on white fabrics
agent.
7.
gap between hydroextraction and drying. 8. Poor whiteness on Cotton / elastane (lycra) fabrics
l The basic whiteness of fabric is very low.
early as possible.
l Natural whiteness of lycra can be
improved by giving a reductive scour before bleaching. 1.5 g/l Sandoclean PCJ Liq. 2 g/l Soda Ash 3 g/l Sodium Hydrosulphite Heat to 75-80C & run 60 min. Cool the bath to 60C & drop bath Run 15 min in a fresh bath containing 0.3 ml/l H2O2 (50%), Rinse cold.
l Improper selection of optical brightening l The selection of optical brighten-
agent.
ing agent must suit both the lycra & the hard fibre in the fabric. Apply Leucophor BMF Liq. 0.8% in a reducing bath (Soduim Hydrosulphite) at pH of about 5.5.
Problems
9. Loss of whiteness retention of cotton / elastane fabrics
Probable Causes
l Poor working practice and poor storage
Remedial Measures
l The following should be avoided:
conditions.
-Unsatisfactory optical whitener. Use only Leucophor BMF/BH Liq. -Drying with air heated by combustion gas or oil -Unsatisfactory softener, use Sandolube HD Liq. and Ceraperm MW Liq. - Do not store white goods in excessive light (natural / artificial). -Exposure to excessive burnt gas fumes (nitrogen oxides) -Lack of air tight & inert packing. -Packing which releases phenolic derivatives.
10.
l Use
appropriate chemicals.
finishing
i) WINCH Ceranine HINI Liq. - Nonionic or Ceranine AS Liq. - Anionic or Ceranine RSFLF Liq. - Amphoteric ii) SOFTFLOW Ceramperm HIS Liq. / Sandolube HD Liq. - Exhaust Ceraperam MW / UP Liq. - Padding iii) TOWELS Dilasoft RWS Liq. Ceraperm HIS Liq. Ceraperm AQUA Liq. 11. Loss of elastic properties in cotton / elastane fibres
l Improper processing methods. l Avoid processing of such blends
fabrics. The temperature in cottage steamers should not exceed 104C (0.2 Kg / cm2 steam pressure) during 30-60 min to maintain the properties of elastane fibres.
l High tension and over heating
DYEING
Problems
1. Uneven shade from ROPE to ROPE
Probable Causes
l Rope length of fabric is not uniform in all
Remedial Measures
l To load fabrics with same rope
winches causes different reel speed affecting effective cycle turn over of the tubes.
l Varying GSM from rope to rope (Higher
GSM fabric has lower rope length, compared to lower GSM fabric of same weight)
l Check tightness factor.
with a new one & avoid use of solvent containing low cost lubricants based on acrylamide. Use Sandoclean PCJ Liq. as a wetting / scouring agent which is based on linear fatty alcohol of natural origin & use Imacol C2G Liq. which forms active film over the fabric keeping the fabric very ductile.
l Pretreat
2.
Clariants concept.
solved properly & dosed. Verify rope speed and chamber loading conditions.
l Use Drimagen ER Liq. as per
the recommendation, which has good disaggregating effect during dye dissolution, uniform distribution during salting stage & pH regulation effect during alkali addition. 3. Dye spots
l Improper dissolution of dyestuff by dissolvl Ensure that any large undissolved
particles do not enter into the dyeing m/c (Always the dissolved dyestuff should pass through a fine stainless steel mesh strainer).
l Use Drigmagen ER Liq. while
cept using 1. Sandoclean PCJ Liq. 2. Sirrix 2UDI Liq. 3. Stabilizer SIFAM Liq. 3. NaOH 3. H2O2 4. Bactosol ARLI Liq. ensures perfectly neutral substrate ready for dyeing with instant absorbancy and no residual peroxide.
Problems
Probable Causes
l Presence of chlorine content in water.
Remedial Measures
l Addition of Drimagen ER Liq.
enables to dose mixed alkali very effectively for perfect & uniform diffusion of dyestuff in to the core of the fibre.
l Using bicarbonate containing hot water l Dyestuff should be dissolved in
acidic medium.
l If the process water passes
some sensitive reactive dyes, the effect of which is very predominant in pastel shades.
concept using Sirrix PK Liq. or Bactosol ARLI Liq. for clearing residual H2O2. dyeing cotton / viscose using Drimarene XN dyes.
caused by the reducing atmosphere created because of the reducing substances present in water (when dyeing temperature is 85 - 95C). 7. Batch to batch reproduction
l If the process - parameters, products &
non- compatible dyestuffs are used the dye-fibre reaction will not attain same end point always.
using identical special chemicals, as per the recommendations preferable using Drimarene CL/K Liq. for pale shades & Drimarene XN for dark shades as these dyestuffs are having least sensitiveness to minor variations in MLR, salt quantity, temperature & time.
l Increase the liquor ratio and
8.
9.
dyebath, the specific gravity of the bath increases. Hence, even fabric surface to surface contact at high speed generates pilling due to heavy friction. 10. Fine creases & unlevelness due to abrasion on cotton & polycotton blends
l Many phenomena appear during the dye-
in dye bath.
ing of textile fabric in the JET dyeing m/c affect the surface of the textiles. They are i) Twisting of the rope ii) Pressure on the fold. iii) More weight on the fold which compresses the fold if no lubrication is applied. iv) Tension on fibres. v) Friction over fabric and also on machine parts with force.
being low compared to synthetic fibres is the primary reason why a universal anticrease product cannot perform very well in every case on every fibre. Only an efficient range of dyeing lubricants can solve all the problems. Imacol C / C2G Liq. - Cotton / Cellulosics Imacol MPE Liq. - For micro polyester Imacol PAM Liq. - For polyamide microfibres
Problems
11. Back - staining of color from the dyed portion to adjacent white or pale colored fabric
Probable Causes
l This problem is visible after knitting the
Remedial Measures
l After treat the dyed fabric using
Sandopur RSK / SW / RSD Liq. depending on the class of reactive dye used, followed by a cationic fixative treatment. (Fastness should be ok in iron test) softener.
dyebath, and Drimarene XN Liq. is the recommended dyestuff, for high degree of levelness.
13.
Tailing effect on critical shades (khakis, Greys, Olives & Browns) Unlevel dyeing with lighter reserved portions
14.
water/ Salt increase the hardness of dyebath and favours aggregation of dye molecules and lead to greater risk of unlevelness. The aggregated dye will tend to migrate more slowly than the single dye molecules or smaller aggregates, so that levelling is not very uniform at the time of alkali fixation.
conditioning the dyebath & sequestering calcium & magnesium not unaffecting the final shade. Dyeing process can be further improved by using. Drimarene CL / K Liq. - For pale shades Drimarene XN Liq. - For deep shades
l Addition of Sandopur R3CZP
Liq. also facilitates easy removal of dye hydroxylates during washing off operations. 15. Poor rubbing fastness
l It mainly depends on the type of substrate l Do protonic pretreatment before
scouring / bleaching.
l Use Optifix F Liq. for removing
16.
using Sandopur RSK / SW Liq. which can dissolve hydrolysed dyestuff and keep them in the wash bath, preventing their redeposition on the substrate.
Problems
Probable Causes
l Use of poor quality salt in dyeing & hard
Remedial Measures
l Correct the hardness of dyebath
using Drimagen ER Liq. & Sandopur R3C ZP Liq., after using water & salt of good quality.
17.
Tone change after soaping on shades produced using vinyl sulphone dyestuffs Uneven appearance due to dye residues on the fabric
l Use
soaping conditions.
18.
dyestuff, using commercially available nonionic/anionic soaps which can remove only dirt impurities.
l Dosage of dye-fixative concentration is in
Sandopur RSK Liq. at pH 9 for complete removal of dye residues (with soft water)
19.
fixative.
l Use Sandofix EC/HCF Liq. conc. l Use Drimarene X-3L Liq. dyestuff
20.
for pale shades to get higher level of light fastness (shades below 1%) i.e a rating of 4.0 (AATC method)
l For med/dark shades Drimarene
XN Liq. or selected Drimarene CL Liq. dyestuffs can be used. invariably lowers the light fastness by at least 1/2 rating.
21.
Twisting of rope causing abrasion, creases, rope marks and uneven dyeing
to entanglement/twisting, free movement of strands will be affected causing slippage. Hence, undue stagnation of certain portion of the fabric in the dyebath can occur and consequently uneven dyeing can result, (dark & light affect on the same length of fabric)
be treated as a skilled job. The length of each rope and the total no. of ropes will have to be determined in advance, based on the weight, sensitivity of fabric, rope length, diameter & gsm.
l The speed of the winch should be
fairly steady and low and the winch should ensure transport of the strand without slippage.
l There should not be too much ac-
cumulation in the bath where the rope strands tend to fall over or shift to the sides thereby causing twisting of ropes.
10
Problems
22. Uneven and patchy dyeing
Probable Causes
l Improper selection of reactive dyestuff,
Remedial Measures
l Use Drimarene CL Liq. which
are medium substative and Sandopur RSK / SW Liq. for washing off unfixed dyestuff.
tive but if its reactivity is medium or lower, fixation will be poor and a hydrolysed dyestuffs should be washed off. Otherwise, unwashed dyestuff appears as patches. In other words, if a color is highly reactive but low exhaustion, this would result in the colour reacting with the fabric even while in the process of adsorption and, at most favourable sites (amorphous regions) the color will strike and cause patchy dyeings.
11
PRINTING
Problems
1. Creases / Folds
Probable Causes
l Improper feeding and batching of fabric.
Remedial Measures
l Proper batching using suitable ex-
pander in batching m/c (Recommended the preparatory department to use Imacol C2G Liq. in the process). 2. Dark & Light prints in Pigment printing
l Improper pretreatment l Fabric should be pretreated thor-
oughly, as per the following method. Sandoclean LFD Liq. - 0.5% Sirrix 2UDI Liq. - 1.0% NaOH flakes - 2.5% Stabilizer SIFS Liq. - 0.4% - 2-4% H2O2 followed by hot wash at 80C & Neutralising.
l Cotton quality l Immature cotton % is more. l Using high density oil. l Use Elfugin Knit-1% in the print
3.
Haziness in pigment printing (mainly on blotch designs) on low gsm fabrics Oil odour
paste.
4.
use
(Aqueous system) with Binder 2000, Printogen RM Liq. & Thickner CN Liq. as the key products. 5. Smudging of OUTLINES
l Poor rheological property of print paste. l Thickening of paste due to electrolytes on l Use 3 gms/kg of Printogen RM
fabric. 6. Presence of HCHO & PCP beyond the limit values for export
l Due to high concentration of binders used
electrolytes
l Use aqueous system of Clariant
in oil system.
l High HCHO fixer. l PCP is also present on grey cotton.
(Printofix concept)
l Use low HCHO fixer (Printofix
7.
Harsh feel
printing. 8. Poor Wet & Dry Rub fastness even after proper curing
l Improper choice of Binder & Fixer. l Use
Binder 2000 Liq. & Printofix Modifier 99 Liq. to improve dry rub fastness. for improving wet rub fastness
9.
10.
12
Problems
11. Thickener consumption is high
Probable Causes
l Thickener is not stirred before use. l Water used for preparing the paste is hard.
Remedial Measures
l Use high speed stirrer before
12.
Flushing Problems
& fabric.
13.
interlock fabric.
15.
Drimarene Turq. Synthetic Thickener. Thiotan AS Liq. Urea Sod bicarbonate before printing. (Pad-Dry-Print).
CLB
&
16.
13
FINISHING
Problems
1. Sewability damage
Probable Causes
l Because of various processing operations,
Remedial Measures
l Use of Sandolube JNF Liq. (for
brittleness on the fabric is developed, which does not allow the needle to penetrate the single knit structure smoothly, but pierces, damaging the knit structure. 2. Poor handle of the fabric after cationic dye-fixing & finishing treatment
l At pH 5.0 to 5.5 most of the cationic soft-
eners exhaust onto cellulose fibres, independent of temperature. An exception to this rule is the softening of dyed cellulosic material which has been treated with cationic fixatives.
l The fibre has a cationic charge due to fixa-
tive. In an acid bath, cationic charge on the fibre and that of softener are activated and repel each other. 3. Dark spots on the fabric
l Using softeners which have poor shear
tory exhaustion of the softner can be achieved using Sandolube JNF Liq. and / or Sandosoft SPK Liq. at pH 7.0
force stability, which forms spots after the emulsion system is disturbed.
stripped, before redyeing, using 1.0 g/l Lyocol RDNI Liq. 2.0 g/l Acetic Acid at 80C, 30 min, Rinse & Neutralise. -Use of Sandolube JNF Liq. (Jet stable & non foaming) in finishing.
l Use Sandoperm MEJ Liq. by
4.
have particle size above 0.1 Micron which cannot penetrate into the core of the fibre to provide an excellent product distribution to give inner softness without looking greasy.
exhaust method or Ceraperm MW Liq. by padding method. (for whites & dyed fabrics) technological properties (mainly supports elasticity), apart from increasing the softness
5.
Very poor handle in thick pique & air-tex fabrics (Dyed goods)
6. 7.
hydrophilic. It becomes hydrophobic because of the oriented adsorption of cationic softener. 8. Poor feel on white fabrics
l If softener is applied by exhaust method, it
Dilasot RWS Liq. & Sandolube HD Liq. in exhaust and Sandolube HD Liq. in padding.
is difficult to exhaust the softener since only non-ionic softeners / anionic / amphoteric are recommended for white goods.
Ceraperm MN or UP Liq.
14
Problems
9. Poor hydrophilicity on polyester on two sided fabrics with one side cotton & other side polyester
Probable Causes
l Functional knitted articles are manufac-
Remedial Measures
l Use Sandotor HV Liq. The
tured having synthetic fabric inside & cellulosic fibre outside (sportswear).
hydrophilic projecting polyether groups on the surface of treated fabrics enables easy penetration of liquid through the capillaries. Or, use Cassapret SRHA Liq. with Ceraperm MW Liq. conc.
l Finish fabrics with Sandolube
10.
Sticking at ends while cutting garments made of cotton & polyester (Two sided fabrics)
cut using knife blades, which gets heated due to large friction involved developing a temperature of about 300C. Hence, it causes melting of synthetic fibres leading to sticking at edges.
l Poor quality of cotton.
products which reduce the friction between the textile and the cutting blades.
11.
given silicone finishing agent treatment in softflow machine using SILICONES which are NOT jet stable. 13. Pin hole seen in a straight line at regular repeat intervals Drip spots in a straight line
l Presence of embedded metal object in the
finishing line.
l Oil drips from a frame, usually on oily l Clean frames at regular intervals.
14.
using Sirrix N Liq. or Sirrix 2UDI Liq. & Acetic acid mixture 50:50.
16.
not have anionic residues, silicone can be added to hot bath at 50C but never heat after adding softener.
l Maintenance of pH not only in the bath but l Use Stripper SS for removing
17.
Oil stains near the edge of tubes & also on the body randomly (Mainly on Navy & Black Shades
also on the fabric is important, otherwise rubbery film formed in finish bath will adhere to the fabric & forms silicone stains, which appears after drying.
silicone stains.
l Navy shades can be produced
using Drimarene XN Liq. instead of vinyl sulphone dyes. using Sirrix 2UDI Liq.
18.
of the fabric.
Many of their dyestuff, pigments and chemicals are patented by CLARIANT LTd. in numerous industrial countries. Registered trade mark of CLARIANT LTD., MUTTENZ, Switzerland and CLARIANT INDIA LTD. are the licensed users of these trade marks. Trademark licensed to CLARIANT LTD. in numerous countries. The signs and appear only at the first mention of the product. The information and recommendations presented here were compiled with the utmost care, but cannot be extended to cover every possible case. They are intended to serve as non-binding guidelines and must be adapted to the prevailing conditions.