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DYEING , PRINTING AND

FINISHING DEFECTS AND
REMEDIES.

The reasons like water, fiber sources & processing

conditions is responsible for defects during wet
processing. However, in order to overcome/
minimize the processing related problems it is
essential to first understand the Symptoms
(problems), Diagnose (ascertain the probable
cause) & Cure (adopting remedial measure).
Some defects of various stages are disscussed
below:

Causes Of Dyeing Defects

Due to Material:

Material having dead fibers or other defective fibers.

Left over of Chemicals after scouring, bleaching etc.

Material not properly singed, desized.

Material not properly mercerized.

Absorbency of the fabric not proper.
Sticking of insoluble material on the fibers.
Impurities are not removed properly.
Uneven heat treatment.

Causes Of Dyeing Defects

Due to Water Quality:
More Hardness of water
Water has metal ions such as iron.
pH of water not proper
Water having more chlorine

Due to Improper Dye Solution:

Improper weight ratio of colors, material and chemicals.
Improper material to water ratio
Improper filtering of concentrated colors.

Dyeing Defects

Bleeding
Its a loss of color when the dyed
fabric is wetted or emerged in
water.
The water here, becomes colored
and may cause discoloration of
other fabrics.
This is usually due to either
improper dye selection or poor
dye fastness.

Crocking
It is the rubbing off of
the color.
It may rub onto
another fabric.
This may be due to
inadequate scoring
subsequent to dyeing.

Shade Bar
It is a horizontal band of
a different hue running
across the fabric.
It may be caused by a
change of filling bobbin
in the loom or a loom
stop and start up

Hole in sulfur dyed fabric

Caused due to tendering which
takes place because sulphur is
converted into sulphuric acid
after oxidation which is harmful
for the cellulosic fibers.
This is a major defect. The defect
occurred after washing the
garment.

Off Shade
It refers to color that doesn't exactly match
the standard or the prepared sample.
This may be due to faulty dye foundation or
application or may be due to variation in dye
lot.

Uneven Dyeing

Batch to batch Shade Variation

Patchy Dyeing Effect

Roll to Roll Variation

Crease Mark

Printing Defects

Flushing/Wicking
Caused due to Low viscosity of
print paste.
It occurs when the printed area
bleeds out into the unprinted
area. The result is a haloing or
shadowing effect around the
outline of the pattern design.

Bleeding
Caused due to Low viscosity of
print paste
It is major defect as it happens
throughout the fabric unless
the viscosity is corrected.

Misfits
A misfit is a print defect caused by improper alignment of the
screens. Also known as out of registration, misfits leave
unprinted areas in the design.
For example, a green leaf may overlap its black outline or
print over another color.

Banding
Defect created by the print heads movement over the substrate.
Use of scanning print head, or a print head that moves back and
forth across the substrate in straight line placing drops of ink at
precise locations along the line.
If the head is not properly aligned, or if the substrate advances
unevenly, the result is a slight horizontal band or line of
unprinted area.

Unwanted pigment
marking on fabric
Caused due to screen has holes
in it that should have been
covered. This could be because
of ageing of the screen and
eventual damage or just
improper exposure to light.

Crack or miss alignment in

transfer printed fabric.
Incomplete transfer of design
from paper to fabric on transfer
printing due to removal of
transfer of paper while the
fabric was still hot.

Finishing Defects

FABRIC FINISHING
A series of processing operations applied to
gray fabrics to enhance their appearance and
hand, properties and possible applications.
Play a fundamental role for the commercial
excellence of the results of textiles

FABRIC FINISHING
The most simple form of finishing is the
ironing or pressing on the fabric.
In finishing , the fabric is subjected to
mechanical and chemical treatment in which
its quality and appearance are improved and
its commercial value enhanced.
Physical finishing techniques(dry finishing
processes) or chemical finishing methods(wet
finishing) are used.

FABRIC FINISHING
Functional finish:
Wearability, Hand, Mechanical resistance,
Easy care, Wettability, Washability,
Deformability, Anti bacterial, Anti fungal,
Soil-proof and Fire-proof ability
Aesthetic finishes:
Aesthetic looks

Unwanted marks on fabric.

Oily stains with dust adhered to
surface which makes the stains
more prominent and difficult to
remove, due to contact with oil
or grease covered exposed
machine parts, careless handling
could be another cause.

Decolorized patch on fabric

Caused due to
chemical spillage on fabric.
Localized excess bleaching.
Localized excess enzyme wash.

Can be result into weakening of

the fabric.

Pin Holes
Holes along selvage caused by pins holding fabric while it
processes through tenter frame.
Major defect if pin holes extend into body of fabric far enough
to be visible in the finished product.

Sanforize Pucker
Results from uneven wetting out on sanforize.
usually caused by defective spray heads.
Fabric will appear wavy or puckering when spread on cutting
table.
Difficult to detect during inspection on inspection machine
with fabric under roller tension.

Bowing
Usually caused by finishing.
Woven filling yarns lie in an arc across fabric width; in knits
the course lines lie an arc across width of goods.
Establish standards of acceptance. Critical on stripes or
patterns; not as critical on solid color fabrics.

Pilling
Pilling is a common fabric defect occurring on knitted and
woven fabrics.
In producing a yarn, long fibers tightly-twisted produce a
serviceable yarn. When short stable fibers are mixed into the
yarn the result is a yarn that will not hold together. The short
staple fibers will separate from the yarn and curl up in a ball,
forming what is referred to as a pill.
Pilling is accentuated by the friction of normal wear, washing
and routine dry cleaning.

Water Spots
Usually caused by wet fabric being allowed to remain too long
before drying; color migrates leaving blotchy spots.

Selvage Torn
Usually caused by excessive tension while processing through
tenter frames.

Cuts or Nicks
Caused by indifferent handling of scissors. snips or
mechanical trimmers.

Soil
Caused by oil, grease or dirt. Often times originating from
a dirty work area or machinery not properly cleaned