woven fabric defects and also knit fabric defects

1. WELCOME TO THE
PRESENTATION

2. MEMBERS INTRODUCTION
Bushra Binte jahangir (161.012.45)
Mehedi hasan (161.022.25)
Mafruja sultana (161.03.25)
Rocky barua (161.018.25)
Sajja rahan (161.010.45)
MD Shakil sadik (161.010.45)

3. Chittagong BGMEA Institute of fashion & technology
Presentation
on
fabric defect.
Subject : Quality management system

4. Introduction
Definition of defect :
i. A fault that spoils the material.
Fabric defect : A Fabric Defect is any abnormality in the Fabric that hinders its
acceptability by the consumer.

5. Importance of fabric defect identification :
• Due to the increasing demand for quality fabrics.
• To avoid Rejection of fabric, It is necessary to avoid defects.
• Price of fabric is reduced by 45%-65% due to the presence of defects
• Company image will go down

6. Major Defects Found in Woven Fabric:
• Bad selvedge.
• Broken ends or warp.
• Broken picks or weft.
• Loose warp.
• Loose weft or snarl.
• Double end.
• Tight end.
• Float of warp.
• Wrong end color.
• Miss pick.
• Double pick.
• Weft bar.
• Ball.
• Hole.
• Oil spot.
• Tails out.
• Temple mark.
• Reed mark.
• Slub.
• Thick and thin place.

7. Bad or defective selvedge:
Bad selvedge in woven fabric due to the faulty weaving. Here,
warp ends being set too far apart for the thickness of the yarn
or in finished fabric.
Reason:
If stretches or looseness is applied on the picks yarn
the bad selvedges is occurred
If the temple is not properly used during weaving.
Loose or Tight selvedge yarn in the Beam.
Remedies:
During weaving loom operator should be careful on
the issues.

8. Broken ends or warp:
A defect in the woven fabric caused by a warp yarn that
was broken during weaving or finishing.
reason:
• Poor preparation
• Weak or irregular yarn
• Excessive warp tension
• If a warp yarn breaks and if the dropper don’t fall
on the dropper bar, then this fault arise.
Remedies:
1. Operator should walk around the machine to
observe this sorts of problem.
2. If the problem is in the dropper bar then, we have
to change that bar.

9. Broken picks or weft:
A filling yarn that is broken in the weaving of fabric
Broken picks or weft
Reason:
A broken pick is the result of a break or cut in
filling yarn, which results in the insertion of a
partial pick in the fabric.
Reasons:
1. If the speed of the machine is too high, then
beat force of the reed to weft yarn will be
too high.
2. If the pressure of the relay nozzle and elca is
too high.
Remedies:
1. We have to reduce speed of the machine.
2. We have to reduce the pressure of relay
nozzle or elca.

10. Loose warp:
This type of fault is produced in woven fabric when the tension of warp yarn is slow.
Loose-warp
Loose warp in fabric Reasons:
1. If the tension of warp yarn is low in warping, then this
fault appears.
2. 2. If the beam contain broken warp yarn.
Remedies:
1. The warp tension in warping should be equal and
uniform.
2. 2. We have to motivate the worker to take care of the
fabric.

11. Loose weft or snarl:
It is produced in woven fabric due to the looseness of filling yarn.
Loose weft
Reason:
1. It happens due to the malfunctioning of the pet.
2. Due to looseness of the filling yarn
3. The wrong alignment of pre-winder to fixed nozzle.
Remedies:
1. The degree of the pet have to be perfect.
2. The pressure of the main valve, relay valve and relay nozzle
should be perfect.
3. The alignment of the presider should uniform and straight.

12. Double ends:
This kind of fault is produced in woven fabric when the two ends of warp sticks get together after sizing.
Double ends
Two ends that weave as one. This happens because
of migration of a broken end to the adjacent reed space
along with the neighbouring end
Reason: After sizing if the two ends of warp sticks
together. And if the worker don’t observe that properly
than those ends can go together through the same heald
eye and can create this problem.
Remedied: Worker have to be very care full about this
matters

13. Tight ends:
If the tension of warp yarn is more than the other ends present in the loom
then this type of fault is produced in woven fabric.
Tight ends
Warp yarn in a woven fabric that was under
excessive tension during weaving or shrank
more than the normal amount.
Reason: If the tension of a warp yarn is more than
the other ends present in the loom then this problem
arise. This over tension produced on warp during
warping and weaving.
Remedies: To solve this problem we have to find
these ends and have to adjust the tension.

14. Float of warp:
If someone pulls the fabric together the cloth roller intentionally or unintentionally
then this kind of defect is produced in woven fabric.
Float of warp
Reason: If someone pull the fabric towards the cloth roller
intentionally or intentionally then we can have this fault.
Remedies: Worker have to be very careful about the button
which causes the fabric to come forward.

15. Wrong end color:
It is produced in woven fabric due to the wrong drawing of colored yarn.
Wrong end color
Reason: It happens due to the wrong drawing of
colour yarn.
Remedies:
1. Worker have to be very careful during doing the job
of drawing.
2. 2. After finding the faults we have to remove the
faulty colour yarn and place a correct colour yarn.

16. Miss pick:
This kind of defect is produced in woven fabric when operator starts
a stopped machine without picking the broken weft from the shade.
Miss pick
Reasons: If a worker start a
stopped machine without picking the
broken weft from the shed then this
type of fault arise.
Remedy: We have to motivate the
worker to do job properly during
time of pick finding.

17. . Double pick:
It is produced in woven fabric when the cutter don’t work properly.
Double picks
Reason: If the cutter don’t work properly.
Remedy: The angle of the cutter should be
changed or its blade should be changed

18. Weft bar:
When count of yarn varies from one cone to another cone
then a bar of weft will be appeared in fabric after weaving.
Weft bar
Causes:
If count of yarn vary from cone to cone or within
the cone then a bar of weft will appeared in fabric
after weaving.
Remedy:
To solve this problem we need to buy yarn with
uniform thickness.

19. Ball:
If the warp is too much hairy then the reed will create ball in warp yarn in between reed and heald shaft.
If the ball is small enough to pass through the dent of reed then those will form the ball in fabric.
Ball
Reason:
If the warp is too much hairy . Then the reed will
create ball in warp yarn in- between heald shaft and
reed .
If the ball is small enough to pass through the dent
of 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 wrap
yarn.

20. Hole:
A fabric imperfection in which one or several yarns are sufficiently damaged to create an opening.
Hole
Reason :
Due to badly tied knot.
Needle break due to slub.
Due to high tension of yarn.
Remedies:
Ensuring uniform yarn tension on all the
feeders, with a Tension Meter.
Rate of yarn feed should be strictly
regulated, as per the required Stitch Length..
Eyelets & the Yarn Guides, should not
have, any fibers, fluff & wax etc. stuck in
them.
The yarn being used, should have no
imperfections, like; Slubs, Neps & big knots
etc

21. Oil spot or stain:
Discoloration on a local area of a substrate that may be resistant to remove by laundering or dry cleaning.
It occurs during spinning, weaving or finishing It is also often seen in the woven fabric.
It is also produced in woven fabric if too much oiling has done on the loom parts.
Oil-stain
Reason :
Due to improper lubrication.
Fibers & fluff accumulated in the needle tricks,
which remain soaked with oil.
Remedies:
Fibers, accumulated in the needle tricks,
cause the oil to seep into the Fabric.
Remove all the Needles & the Sinkers of
the machine, periodically.
Cleaning the grooves of the Cylinder &
Dial of the machine thoroughly.
Blowing the grooves of the Cylinder, Dial
& Sinker ring, with dry air after cleaning

22. Tails out:
This kind of fault is produced in woven fabric if the cutter doesn’t work properly.
Tails out
Cause:
If the cutter don’t work properly then this
kind faults arise.
Remedy:
To solve this problem either we have
change the degree of cutter or we have to
change the cutter blade.

23. Temple mark:
If the placement of ring in the temple bar is wrong or
the pressure of temple to the fabrics is too high then this type of fault is produced.
Temple mark
Reason: If the ring of the temple is damaged then we
will have this fault.
Remedy: The bristle of the temple should be sharp
and easy going

24. Reed mark:
In woven fabric, a crack between the groups of warp ends either continuous or at intervals.
It’s may be caused by the wrong drawing-in of the warp or damage to the reed wires.
Reed mark
Causes:
A crack between groups of warp ends, either
continuous or at intervals, which can happen due to
improper spacing of dents.
If the dent of the reed is damaged then we will have
this kind of faults.
Remedy:
The reed have to be changed .

25. Slub:
If the yarn contains unexpected slub in it then those slub will be appeared in the fabric as a fault.
Slub

26. Thick and thin place:
Fabric defect in which fabric count varies more than a specified percentage from the intended count.
If the thick or thin place is more than one inch (2.54cm) wide then
it is considered as a major defect in fabric grading.
Thick place
Reasons: This comes due to the thick, thin
places that presents in the fabric.
Remedy: The yarn have to be checked by
QC during the time of procurement to avoid
these faults.

27. Defect of knit fabric

28. Knitted Fabric Defects :
Faults or defects in knitting production can be caused in different ways and quite a few of them cannot
related to just one cause. The following explanations are expected to be helpful in trying to locate the
causes of these faults easier.
Reasons of fabric defects:
Yarn manufacturing defects
Fabric manufacturing defects
Fabric processing faults or defects. Such as dyeing faults, printing faults or finishing faults.
Sources of fabric faults:
The sources of faults could be:
Faults in yarn and the yarn package
Yarn feeding and yarn feed regulator
Machine setting and pattern defects
Machine maintenance
Climatic conditions in the knitting plant

29. List of Knitting Faults Found in Knitted Fabric:
Knitted fabric faults are very different in nature and appearance and are often superimposed.
The following knitted fabric defects are found in knitted fabric production.
• Broken ends, holes or cracks
• Drop stitch
• Cloth fall-out or pressed-off stitches
• Snagging or snags
• Tuck or double loop or stitches
• Bunching-up
• Vertical stripes
• Horizontal stripes
• Soil stripes
• Color fly or color tinges
• Distorted stitches or deformed or tilted loops

30. Broken ends, holes or cracks
Broken ends, holes or cracks:
During stitch formation the yarn had already broken in the region of the needle hook.
Depending on the knitted structure, yarn count, machine gauge and course density, the holes have different sizes.
This size can therefore only be estimated if the comparable final appearance of a comparable fabric is known.
Possible causes:
a) Yarn parameters , High yarn irregularity
Incorrect yarn input tension setting, yarn running-intention is too high.
Poorly lubricated yarns, Yarn is too dry.
b)Yarn damage
d) Relation between cylinder and dial loop not correct; yarn feeder badly set;
defective knitting elements.
Remedies:
Yarn strength must be sufficient to with stand the stretch as well as uniform.
Use proper count of yarn.
Guide blowing.
Correctly set of yarn feeder.
Yarn regularity control.

31. Drop stitches
These are the result of a defective needle. They also occur when a yarn is not properly fed during stitch formation,
i.e., not properly laid-in the needle hooks. These are the unlinked knitted loops.
Drop stitches
Possible causes:
a) In accurate insertion of the yarn into the needle hook;
b) Broken needle hook;
c) Due to high yarn twist and low fabric take-down-tension the knitted
loop could fall out of the hook;
d) Yarn feeder wrongly threaded-in;
e) Bad take-up;
f) Very dry material;
g) Insufficient yarn tension.
Remedies:
• Correct take-up of the fabric & correct fabric tension.
• Ensure uniform yarn tension on all the feeders with a Tension Meter.
• Proper feeding of yarn during loop formation.
• The fabric tube should be just like a fully inflated balloon, not too tight or too
slack.
• Needle should be straight & well.

32. Cloth fall-out or Pressed-off stitches:
It is an area consisting of drop stitches lying side by side.
They can occur either when a yarn is laid-out or when it breaks without any immediate connection
Cloth fall-out can occur after a drop stitch especially when an empty needle with closed latch runs into
the yarn feeder and removes the yarn out of the hooks of the following needles.
. Cloth fall-out or Pressed-off stitches:
Possible causes:
Yarn breaks before the yarn feeder
Yarn package winding faults, poor package buildup;
Fiber fly block the yarn guides, feeders etc.
Remedies:
Needle detectors, should be set precisely, to detect the
closed needles & prevent the fabric tube from
completely pressing off.
Make sure all the latches of needle are closed with
feeding yarn after a drop stitch.
Proper yarn tension should be maintained, on all the
feeders

33. Needle marks or Vertical stripes:
Vertical stripes can be observed as longitudinal gaps in the fabric.
The space between adjacent wales is irregular and the closed appearance of the fabric is broken up in an unsightly manner.
Vertical stripes and gaps in the fabric are often the result of a meager setting,
Needle marks or Vertical stripes:
Possible causes:
Twisted or bent needle hooks;
Stiff latches and needles;
Incorrect closing of the hook by the latch;
Heavily running needles;
Damaged dial and cylinder;
Damaged needle latch and needle hooks;
Damages on other knitting elements.
Remedies:
Yarn count should be selected as machine gauge.
Stitch size should be correct.
Selection of needle properly.
Needle should be straight as well as from broken latch

34. Horizontal Stripes:
These are caused by unevenness in the courses; they traverse horizontally and repeat themselves regularly or irregularly.
Possible causes:
Deflector in dial cam brought into tuck position.
Deflector not completely switched off. Needle can still grip the
yarn and forms a tuck loop.
Yarn feeder badly set.
Differences in the yarn running-intension.
Courliering not constant at all feeders.
Jerky impulse from fabric take-up.
Remedies:
The machine must be mounted horizontally.
Needle dial & cylinder must be exactly centered towards one
another.
Replace that bobbin.
Yarn tension & stitch should be controlled uniformly.
Yarns of same lot should be used.
Check cams positioning

35. Barriness :
Barriness defect appears in the knitted fabric in the form of horizontal stripes of uniform or variable width.
Actually barre'ness is the periodic lateral irregularities
Possible causes:
Individual yarns differ with respect to
count, properties or structure;
Different course lengths in feeders.
Knitting of yarns which differ in colour;
Yarns dye differently during piece dyeing.
Remedies :
• Ensure uniform Yarn Tension on all the feeders.
• Ensure that the hardness of, all the yarn packages, is
uniform, using a hardness tester.
• Ensure that the yarn being used for Knitting is of the
same Lot / Merge no.

36. Bunching-up or Thick and Thin Places:
Visible knots in the fabric are referred to as bunching up.
They appear as beads and turn up irregularly in the fabric. Can build up resulting in a ‘cloudy’ appearance.
More irregular the yarn, more pronounced is the ‘cloudy’ appearance.
Possible causes:
• Thick and thin places in the yarn.
• Fabric take-up too weak.
Remedies:
• Specify the quality parameters of the yarns to be used for
production to the yarn supplier.
• Preventing count or lot mixing.
• Maintaining uniform yarn tension..
• Fabric take-up should function properly.

37. Snagging:
Snags mainly occur while processing filament yarns.
The tendency towards snagging can be reduced by using yarns
with a coarser single filament count, lesser crimp elasticity and higher twist.
Causes:
During knitting all mechanical influences, caused by rough surfaces on yarn guide
elements, yarn feeders, needles, fabric take-up, etc. have to be avoided. Even after
knitting some snags can appear especially during fabric setting,
Remedies:
Inspect & rectify the fabric contact points on all the machines (Soft Flow Dyeing,
Tumble Dryer & Centrifuge etc), on which snagging is taking place.
Using yarn with a coarser single filament count, lesser crimp elasticity and higher
twist.

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