Problem count | Categories and subcategories of dyeing problems | Causes |
A | Unlevelness | Due to bleaching and dyeing conditions |
01 | Ending problems |
Poor dyes dispersion. Unsuitable dye combination. Wrong dyeing method. |
02 | Cloudy dyeing |
Inadequate pretreatment (in bleaching). Irregular winding. Wrong loading of robbins (overload - tight winding). Improper liquor circulation. Improper liquor to material ratio. Foaming during dyeing. Wrong dyeing method. |
03 | Pale areas |
Improper desizing and bleaching. Salt deposition during bleaching. Imbalance of loaded material. |
B | Unlevelness | Due to material |
04 | Barriness |
Variations in temperature during fibre manufacturing (texturing). Variations in density of the material. |
C | Unlevelness | Due to other reasons |
05 | Skitterness |
Inadequate pretreatment (e.g., desizing). Different fibres. Poor penetration. Poor solidity of fibre blends. Tension during weaving, knitting, and mercerising. |
06 | Listing |
Different setting temp. Tension during weaving, knitting, mercerising and improper rolling of selvedges. |
07 | Pale areas after dyeing | Due to vapours of acid, chlorite, formaldehyde. |
D | Reproducibility | Due to dyes, dyeing method, and finishing |
08 | Variation of shade |
Dyes unstabilities. Dyes sensitivities to metal ions. Use of hard water. Different chemical nature combination. Different liquor ratio. Unsuitable dye combination. |
09 | Difference in shade (concentration) |
Different dye pick-up. Different nature of dyes. Different dyeing program. Different saturation point. |
10 | Precipitates in the dye bath |
Different chemical nature. Different solubility of dye. Stability at different temp. |
E | Fastness properties | |
11 | Poor light fastness, wet & rub fastness |
Different saturation of dyeing and printing of dyes. Catalytic fading due to unsuitable dye combination. Different chemical properties of dyes. Thermal migration due to finishing. Different chemical nature of finishing agent. |
F | Spots / marks | Due to material |
12 | Singeing marks | As a result of singeing before dyeing fibre tips exhibit higher affinity for dyes. |
13 | Change of shade |
Dye is sensitive to metal ions. Difference in acidity / alkalinity. Ionic nature of finishing chemicals. |
14 | Specks | Due to salt deposition. |
G | Appearances of the Goods | |
15 | Dimensional stability (shrinkage) |
Inadequate setting of fibre. Lengthwise distortion during mercerising and dyeing. Relaxation during bleaching. |
16 | Creasing |
During scouring and heat setting. Due to tight woven fabric. Uneven batching of fabric. Mechanical friction. |
17 | More effects | Inadequate setting and batching. |
18 | Pilling (staple fibres) | Inconsistent dimensional stability due to shrinkage. |
H | Other Problems | |
19 | Dark or pale selvedges |
One sided liquor feed. Alkali residues in the goods. Uneven temperature in machine. |
20 | Spots |
Due to condensation drops. Foam spots due to padding. Alkali residues in the goods. |
21 | Ending |
Dye substantivity. Dye sedimentation. Poor penetration. Migration. |