Major defects found in woven fabric

Major Defects Found in Fabric

Various types of faults found in the woven fabric have been mentioned below:

1. Bad or defective selvage

Bad selvage in the woven fabric due to faulty weaving. Here, the warp ends are set too far apart for the thickness of the yarn or in the finished fabric.

Causes

a. If stretches or looseness is applied on the picks yarn the bad selvages have occurred.

b. If the temple is not properly used during weaving.

c. It is mandatory to pull the selvage’s yarn through the Healed Eye and Healed shaft. If it does not complete carefully the selvages will be poor.

d. Loose or Tight selvage yarn in the Beam.

e. Bad beaming causes the bad selvages of the fabric.

Remedies: During the weaving loom, the operator should be careful about the above issues. The stretching width should be set very carefully.

2. Broken ends or warp

Woven yarn is a defect in the woven fabric that breaks during weaving or finishing.

Causes

a. If the yarn quality is low, breakage may occur.

b. If a warp yarn tension is high, then this fault arises.

Remedies: Must have to use good quality yarn in the warp beam & ensure proper tension.

3. Broken picks or weft

A filling yarn that is broken in the weaving of fabric.

Causes

a. If the beat-up motion is done before the insertion of full pick, this type of fault may occur.

b. If the pressure of the relay nozzle is too low, then this fault may occur.

c. Faulty let off and take up motion.

d. Faulty weft stop motion.

Remedies: We have to reduce the speed of the machine. We have to maintain the pressure of the relay nozzle is optimum. Proper timing of picking and beating should be maintained.

4. Loose warp

This type of fault is produced in the woven fabric when the tension of the warp yarn is low.

Causes

a. If the warp yarn breakage during winding.

b. If the tension of warp yarn is low in warping, then this fault appears.

c. If the weaver's beam contains broken warp yarn from sizing.

d. During the weaving due to warp breakage, this fault may occur.

Remedies: The warp tension in warping should be equal and uniform. We have to motivate the worker to take care of the fabric.

5. Loose weft or snarl

It is produced in woven fabric due to the looseness of the filling yarn.

Causes

a. It happens due to the malfunctioning of the programmable felling tensioner.

b. Due to the looseness of the filling yarn.

c. The wrong alignment of the Pre-winder to the fixed nozzle.

Remedies: The degree of PFT has to be perfect. The pressure of the main valve, a relay valve, and a relay nozzle should be perfect. The alignment of the pre-winder should be uniform and straight.

6. Double ends

This kind of fault is produced in the woven fabric when the two ends of warp sticks get together after sizing.

Cause: After sizing if the two ends of warp stick together. And if the worker doesn’t observe that properly then those ends can go together through the same heald eye and can create this problem.

Remedies: The knotting should be done very carefully so that, two or more ends cannot be knotted with each other. Workers have to be very care full during weaving.

7. Tight ends

Tight ends mean over-tension in warp threads.

Causes

a. If the tension of warp yarn is more than the other ends present in the loom then this problem arises.

b. This tension is produced on warp during warping and weaving.

Remedy: To solve this problem we have to find these ends and have to adjust the tension.

8. Float of warp

If someone pulls the fabric together with the cloth roller intentionally or unintentionally then this kind of defect is produced in woven fabric.

9. Miss pick

This kind of defect is produced in the woven fabric when the operator starts a stopped machine without picking the broken weft from the shade.

Cause: If a worker starts a stopped machine without picking up the broken weft from the shed then this type of fault arises.

Remedy: We have to motivate the worker to do the job properly during the time of pick-finding.

10.  Double pick

It is produced in the woven fabric when the cutter doesn’t work properly.

Causes

a. If the receiver receives double yarn instead of a single yarn.

b. If the spindle doesn’t work properly.

c. It may be happened because of the migration of a broken end to the adjacent reed space along with the neighboring end.

Remedies:  The spindle should be changed. The loom should be cleaned.

11.  Weft bar

When the count of yarn varies from one cone to another cone then a bar of weft will be appeared in the fabric after weaving.

Causes: If the count of yarn varies from cone to cone or within the cone then a bar of the weft will appear in the fabric after weaving.

Remedy: To solve this problem we need to buy yarn with uniform thickness.

12.  Ball

When the warp is too much hairy then the reed will create a ball in warp yarn in between the reed and held shaft.

Causes

a. If the warp is too much hairy, then the reed will create a ball in the warp yarn in between the heald shaft and reed.

b. If the ball is small enough to pass through the dent of the reed then they will form the ball in fabric. Remedy: To solve this problem we have to change the reed, or reduce the tension of the warp yarn. 

13.  Hole

A fabric imperfection in which one or several yarns are sufficiently damaged to create an opening.

Causes

a. If we try to cut the balls of the fabric which makes the look of the fabric poor then it will be cut along with the warp. This will create a hole in the fabric. These holes become bigger after the finishing process.

b. It can happen due to the clash between the fabric and the sharp edge of the machine parts.

Remedies: we need to control ball-making. Workers need to be careful when transporting fabric from one floor to another to avoid sharp points tingling with the fabric.

14.  Oil spot or stain

Discoloration on a local area of a substrate that may be resistant to removal by laundering or dry cleaning.

Causes

a. Due to the carelessness of the maintenance workers and the machine operatives, oil spills over parts that come in contact with the fabrics, and stains are produced.

b. Oil spots on the fabrics are caused by too much oiling on loom parts from other sources.

Remedies: Use stain remover. 

15.  Reed mark

In woven fabrics, a crack between groups of warp ends either seamlessly or breaks. It’s maybe caused by the wrong drawing-in of the warp or damage to the reed wires.

Causes

a. A crack between groups of warp ends, either continuous or at intervals, which can happen due to improper spacing of dents.

b. If the dent of the reed is damaged then we will have this kind of fault.

Remedy: The reed has to be changed.

16.  Slabs

If the yarn contains unexpected slabs in it then those slabs will appear in the fabric as a fault.

Causes: If the yarn contains an unexpected slab in it, then that slab will appear in the fabric as a fault.

Remedy: The quality controller has to be very careful about the quality of the yarn. 

17.  A thick and thin place

Fabric defect that's why fabric count varies more than a specified percentage from the intended count. If the dense or thin space is more than an inch (2.54 cm) wide, it is considered a major defect in fabric grading.

A segment of yarn at least ¼ inch (0.6cm) long that is noticeably thicker than adjacent portions of yarn is called the thick place. A portion of a yarn that is at least 25% smaller in diameter than the adjacent part of the yarn is called the thin spot. 

18.   Shade variation

The fabric has an equal dye affinity and if pretreatment e.g. scouring and bleaching has taken place in different machines.

Causes

a. The liquor ratio changed in each batch,

b. The fabric ropes passing through the nozzle are changed.

c. The dyeing procedure is different for each batch.

d. Temperature and added bulk chemicals changed.

E. Low-quality water especially PH, hardness, and sodium carbonate content.

Remedies: Check that the fabric has the same dye affinity and if pretreatment e.g. scouring and bleaching have taken place in a different machine. Use the same stand procedure for each batch. Check your water supply daily, especially the PH, hardness, and sodium carbonate content. 

19.   Crease mark

Causes

a. Lack of balance in construction of the fabric v Pressure of padder roller

b. Faulty plaiting device.

c. Slack on tight selvage causes crease at an angle to eh selvage.

d. Improper fabric movement.

Remedies: Anti-creasing agents are used to avoid the crease mark problem. Proper maintenance of the machine 

20.   Hairy fabric

Cause: The type of fabric fault comes due to the hairiness of the yarn.

Remedies: The yarn has to be checked during the time of procurement to avoid these faults. We need to buy good yarn. 

21.   Knot

Causes

a. If the yarn breakage during winding, warping, sizing, and weaving this fault may occur.

b. Improper loom cleaning.

c. Unclean environment.

Remedies: The extra foreign matter can be pulled out with a plucker. Combing in both directions rectifies the resultant patch.

22.   Gout

Causes

a. Improper loom cleaning.

b. Unclean environment

Remedy: The extra foreign matter can be pulled out with a plucker. Combing in both directions rectifies the resultant patch.