2. Prepared By : Mazadul Hasan sheshir
ID: 2010000400008
13th Batch (session 2009-2013)
Department : Wet Processing Technology
Email: mazadulhasan@yahoo.com
Blog : www. Textilelab.blogspot.com (visit)
Southeast University
Department Of Textile Engineering
I/A 251,252 Tejgaon Dhaka Bangladesh
Prepared By :

3. Total Textile Process at a Glance

4. Knitting Faults
Hole: Hole can be three types Hole, Pin hole, Star hole.
• Causes:
• Broken Needle.
• Improper cleaning.
• Yarn breakage at knot.
• Very high yarn twist.
•
Picture:
Hole
Remedies:
• Properly M/C cleaning.
• Dust removes by the air gun.
• Needle broken check.

5. Loop Out:
Causes:
 Needle broken.
Picture:
Remedies:
 Change the broken needle.

6. Loop:
Causes:
• Missing feeder of the yarn.
• Fly or dust contains.
Picture:
Loop
Remedies:
• Properly yarn is passing to the feeder.
• Remove dust or Fly from the Air gun.

7. Lycra out:
• Elasticity missing
• Breaking of Lycra yarn
• Too much tension on yarn
• Improper working of feeder
• Too high Lycra running in tension
Picture:
Lycra out
• Replace the Lycra yarn where the Lycra Missing.
• Insure working of feeder.

8. • Uneven yarn.
• Yarn breakage to thin places.
Picture:
Setup
• Use smooth yarn.
• Yarn repair to the thin place.

9. Fly Knitt:
Causes:
• Fly contamination to produce Fly Knit
Picture:
Remedies:
• Fly is removing by the help of Sesser.

10. Patta:
Causes:
• Patta is creating by Machine parts fault.
Picture:
Patta
Remedies:
• To repair the M/C parts.
Note: After Fabrications Patta can’t remove any process.

11. Dyeing Faults
Causes:
 Uneven pretreatment (uneven scouring & bleaching).
• Improper color dosing.
• Using dyes of high fixation property.
• Uneven heat-setting in case of synthetic fibers.
• Lack of control on dyeing m/c
Remedies:
• By ensuring even pretreatment.
• By ensuring even heat-setting in case of synthetic fibers.
• Proper dosing of dyes and chemicals.
• Proper controlling of dyeing m/c
• MA SOAP Ne (.3 g/l) 900X30/ 2 time.

12. Batch to Batch Shade Variation:
Causes:
• Fluctuation of Temperature.
• Improper dosing time of dyes & chemicals.
• Batch to batch weight variation of dyes and chemicals.
• Dyes lot variation.
• Improper reel speed, pump speed, liquor ratio.
• Improper pretreatment.
Remedies:
• Use standard dyes and chemicals.
• Maintain the same liquor ratio.
• Follow the standard pretreatment procedure.
• Maintain the same dyeing cycle.
• Identical dyeing procedure should be followed for the same depth of the Shade.

13. Crease Mark:
Causes:
Poor opening of the fabric rope
• Shock cooling of synthetic material
• If pump pressure & reel speed is not equal
• Due to high speed m/c running
Remedies:
• Maintaining proper reel sped & pump speed.
• Lower rate rising and cooling the temperature
• Reducing the m/c load
• Higher liquor ratio

14. Finishing Faults:

15. Squeezer Mark:
•Machine problem or folding.
•Folded the fabric after properly dryer.
Dirty spot:
Fabric is placed dirty place
•Contamination of dust.
•E2R + Lad quest + KRCP – 900 x 60’

16. Cutting Faults
Causes:
• Fabric line don’t match.
• Cutting machine move un direction wise
Remedies:
• Fabric line must be match.
• Knife moves marking direction wise

17. Unfused edge
• High temperature produced during cutting can fuse fabric
edges by melting.
• Use of anti-fusion (heat absorbent) paper.
• Spraying silicon lubricants on the blade.
• Less cutting speed.
• Reducing the height of the lay.

18. Printing Faults
• Color spot
• Color shade
• Basic Shade
• Color missing
• Color Reject
• Un shade color
• Un complete print
• miss Print

19. • Printing screen block.
• Printing paste short.
• Clean the Printing Screen
• Printing paste is available on the printing screen

20. Miss Print:
• Drying the printing paste
• Less amount paste give the on the fabric.
• Curing process is not properly use
Picture:
Miss print
• Sufficient paste is required on to the fabric.
• Curing process must be done

21. • Needle broken
• Bobbin thread out
• Broken Needle change
• Bobbin change

22. weak stitch
 Less thread tension.
• Lying paper missing.
• Correct thread tension should be used.
• Lying paper properly used.

24. problem of stitch formation
• Thread is tearing due to stitch formation.
• Needle is broken due to stitch formation.
• Bonding the tearing thread due to proper stitch formation.
• Broken needle is changed.

25. Seam puckering
• Very high or low tension stitch cause seam
puckering.
• Very high twisted thread is used.
• Normal tension thread is used due to stitch
formation.

26. Name of garment defects/ Faults:
– Spirality
– Broken Buttons
– Broken stitching
– Defective snaps
– Different shades within the same garment
– Dropped stitches
– Exposed notches
– Exposed raw edges
– Fabric defects
– Holes
– Inoperative zipper
– Loose sewing threads
– Misaligned buttons & holes
– Needle cuts
– Open seams
– Loose thread
– Stain
– Unfinished buttonhole
– Zipper too short

27. Spirality:
• Yarn twist too high.
• Yarn quality is very poor.
• Bad combination between yarn twist & machine rotation direction.
Picture:
Spirality
• Control of yarn twist (yarn twist should never be above 700 try/m).
• Reduction of feeder number.
• Appropriate finishing reduces fabric spirality.

28. Different shades within the same garment:
• Uneven to batch missing shade.
• Different Batch mixing for same garment.
• One batch fabric shade is used for same garment
in every part.
• Shade is marking each part due to fabric cutting.

29. Hole:
• Very stiff & dry yarn
• Fluff
• Improper cleaning
Picture:
• Use a fabric fault detector.
• Air humidification
• Use of yarn having lower hairiness.

30. Stain:
• INK, Food and drinks that are spilled on the garment
stain. are one of the most common ways clothing
becomes stained.
Picture:
Stain
• Shout Stain Solver is remove garment stain

31. Garments Finishing Faults:
• Shrinkage
• Dirty sport
• Iron spot
• Oil line
• Alter
• Dye sport
• Rejection
• Unwanted marks on fabric
• Decolorized patch on fabric
• Pin holes
• Sanforize Pucker
• Pilling
• Water Spots
• Cuts or Nicks
• Seam Tears
• Soil
• Loose Threads
• Folding Defects

32. Unwanted marks on fabric:
Causes:
 Oily stains with dust adhered to surface which
makes Unwanted marks on fabric
Picture:
Remedies:
• Sun Shine water removes the unwanted mark
on fabric.

33. Pin holes:
Causes:
• 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.
Picture:
Remedies:
• Before fabric spreading hole part is remove from the cutting fabric.

34. Seam Tears
• Frequently caused by the turning equipment used toreverse garments in
finishing.
Picture:
Seam tear
• Seam Stitch is again where place Seam Tears.

35. Shrinkage:
Causes:
• Short fibre yarn create shrinkage problem on to the
fabric.
• High twisted yarn/thread is the reason of shrinkage.
Picture:
Shrinkage
Remedies:
• Steam iron is used.
• Better quality yarn shrinkage problem reduce.

36. Dirty sport:
• Dirt, Dust & other impurities is the cause the dirty
sport.
Picture:
• E2R + Ladiquest + KRCP – 900 x 60o
1 g/L 1 g/L 1 g/L

37. Iron spot

38. Alter:
Causes:
• Stitch drop, Size defect.
Remedies:
• Stitch open & new stitch is drop.
• Actual size is measured to new body.
Rejection:
Causes:
• Garments Hole is the main reason of rejection.
Remedies:
• There is no remedy in garments rejection this garments is
totally reject.

39. The fabric & Garments fault is the common reason. This
problem is must be occurred during fabric & garments
processing. Then we try to remedies this problem in
various ways. But initially if we more carefully this
faults, and some step is taken to prevent this faults
then faults percentage is reduce.

40. Conclusion:
We have done project work is very carefully with
successfully. Our Industry Every person is very
helpful & Positive attitude. We found the Fabric &
Garments fault with its remedies in every division.
This project work is very essential in our job life.

43. 1. Yarn Manufacturing Technology
Link : http://www.facebook.com/pages/Yarn-Manufacturing-Technology/485014954866808
2. Fabric Manufacturing Technology
Link : http://www.facebook.com/pages/Fabric-Manufacturing-Technology/459520217425605
3. Garments Manufacturing Technology
Link : http://www.facebook.com/pages/Garments-Manufacturing-
Technology/472364799463126
3. Wet processing Technology
Link : http://www.facebook.com/pages/Wet-Processing-Technology-Dyeing-/468645219825404
4. Fashion-Design-and-Technology
Link : http://www.facebook.com/pages/Fashion-Design-and-
Technology/587655294583875?ref=ts&fref=ts
My Facebook Textile related Pages
http://www.textilelab.blogspot.com (Visit )