This presentation is based on problems & remedies in wet processing of cotton. starting from grey room to finishing.

1. Problems & Remedies
in Wet Processing of
100% Cotton (Woven)
- Pathik Shroff

2. PROCESS SEQUENCE
Grey Room Shearing Cropping Singeing
Desizing
Scouring
Bleaching
Mercerization
Dyeing
Printing
Finishing

3. GREY ROOM
Sr .no. defects causes Remedies
01 Thick & thin
place .
1.Immature fibre .
2.Staple length.
3.Neps.
4.Drafting limitation
1.Selection of raw material.
1a.Mature fibre.
2.Good staple length.
3.Maximum Neps should be
removed (carding & combing).
4.set Required draft.(no of
doubling , speed of drafting
roller.)
03 Weft bar Count variation
Density of pick more.
 use Less variation of weft
count.
Required density of weft.
04 End & Pick
missing
•Warp stop motion not working
on loom at warp break.
•Moving empty shuttle
•Breakage of weft thread
•Use warp stop motion as per
break .
•New extra thread joining
•Mending.

4. Weft bar
Missing Ends & Pick

5. SHEARING & CROPPING
Sr .no. defects causes Remedies
01 Cut or
holes
damage
to
fabrics.
1.Presence of metallic
particle on fabric.
2.Due to abrading
action.
1.Use magnetic metal
detector in feeding device.
1a.Removal of metal particle
from grey fabric.
2.Covering the emery roll
with a piece of cloth which
reduce abrading action.
02
Rough
&
uneven
surface
of
fabric.
Inefficient Sharpness
of blade.
Grinding to blade & proper
position & adjustment of
blade

6. HOLES, CUT

7. SINGEING
Sr .no. Defects Causes Remedies
1 Incomplete
singeing
1. low flame height
2. fast fabric speed
3. High Moisture
content
1. flame height 4”- 6”
2. Fabric speed 90-120 m/min
3. Ensure moisture content should
be 6-8%
2 Uneven
singeing
[lengthways]
1. Change in fabric
speed during
Singeing
1. Maintain Uniform fabric speed
through out
Singeing
3. Thermal
damage or
Reduction in
tear strength
1. Too slow fabric
speed
2. close distance
between the fabric and
the burner
1. Fabric speed must be set
Above 60-70 m/min
2. From 6-8 mm upto 6-20 mm
distance between
the fabric and the burner

8. FABRIC BEFORE SINGEING & AFTER SINGEING

9. DESIZING
Sr. No. Defects Causes Remedies
1. Incomplet
e desizing
1. Inappropriate desizing
bath pH
Set pH of bath depend on
enzyme
type of enzyme pH
1. Malt extract 6-7.5
2. Pancreatic 6.5-7.5
3. Bacterial 5.5-7.5
2. Inappropriate desizing
bath temperature
Temperature of bath must be
80-95◦ C .
3. Insufficient fabric pick-
up
3. Use of wetting Agent
4. Deactivation of
enzyme due
to presence of metals or
other
contaminants
4a. Use of soft water
4b. Use of appropriate
sequestering agents

10. Sr. No. Defects Causes Remedies
2 Uneven Desizing 1. Foaming in the bath 1. Use of appropriate
defoamers
2. Inappropriate bath
temperature
2. Ensure bath temperature of
bath 80-90◦ C
3. Non-uniform washing
after
desgizin
3. Ensure Hot wash at 95◦C for
10-15min Thorough and
uniform
washing after desizing
4.Preferential drying of
outer
layers of the batch
4a. Covering the batch with
polythene or other suitable
sheet
4b. Keep the batch rolling
5.Temperature variation
during digestion
5. Covering the batch with
polythene or other suitable
sheet

11. SCOURING
Sr. No. Defects Causes Remedies
1. Inadequate
absorbency or
High residual
impurities
Inadequate
concentration of
scouring chemicals
Check recipe
Sodium carbonate - 2-3%
owf
Anionic detergent - 1-3 g/l
Incompatible or
ineffective
surfactant/wetting agent
Compatible and effective
surfactant/wetting agent
Water hardness or
ineffective chelating
agents
Use of soft water or
effective
chelating agents
2 Tendering or
damage or
loss in strength
1. Presence of air in the
machine, leading to the
formation of oxycellulose
2. Contamination of iron
1a. Exclusion of air
1b. Use of mild reducing agent
2a. Water purification
2b. Use of appropriate
complexing agent

12. BLEACHING
Sr. No. Defects Causes Remedies
1. Uneven whiteness 1. Use of inappropriate
surfactants
2. Water hardness
3. Irregular chemical feeding
4. Condensation or water marks
5. Foaming in the bath
6. Inappropriate use of
defoamer
1. Appropriate/ compatible
surfactants
2. Soft water or use of
sequestering agents
3. Optimum chemical feeding
4. Optimum steaming conditions
5. Appropriate use of defoamer
6. Appropriate use of defoamer
2 Resist marks 1. Deposits of insoluble salts
of
surfactants
2. Redeposition of impurities
1. Use of soft water or
appropriate chelating agents
2a. Careful selection of
scouring auxiliaries
2b. Thorough washing after
scouring

13. BLEACHING
Sr. No. Defects Causes Remedies
3. Harsh handle 1. Silicate deposits 1a. Use of organic
stabilisers
1b. Optimum control
of pH
(low pH reduces
silicate
solubility)
1c. Thorough washing
after
bleaching
4. Fibre degradation OR
Reduction in fibre
strength
1. Metal contaminants 1a. Treatment of
water to
remove metal
contaminants
1b. Use of appropriate
complexing agents

14. Sr.
No.
Defects Causes Remedies
5. Low degree of
whiteness
(Bleaching fabric
by pad-Steam)
1.Residual sodium
acetate after
Neutralization
2.Too low bleaching pH
3.. short steaming time
4. low steaming
temperature
1.Thorough rinsing after
Neutralization
2. Ph 10-11
3. Steaming 60-90min
4. Steaming at 90-95◦ C
Check no leakage of
steam

15. MERCERIZATION
Sr. No. Defects Causes Remedies
1. Low
increase
in lustre
1.Low concentration of
Caustic
2. Insufficient fabric
stretching
while on the frame
3. Dwell time
1.Caustic concentration must be 52◦
Tw or 26 Be
2. Use of tensioner device
3. dwell time should be 60 sec
2. Poor
shrinkage
control
1. Insufficient fabric
stretching
while on the frame
2. Too much caustic on
the fabric
as it comes off the frame
1. Optimum fabric stretching
while on the frame
2. Removal of excess caustic
from the fabric before it comes
off the frame

16. DYEING
Sr.
No.
Defects Causes Remedies
1. 1. Poor Washing
Fastness in Direct
Dyeing
1. Dye
substantivity,
too high
2. Inherent low
fastness
properties of the
dyes
1a. Treatment with Copper salts
Copper sulphate 0.5-2% owf, Acetic acid
0.5% temp- 80◦C time 30-45min
1b. Treatment with chromium
compound
Potassium dichromate 2-3% owf
Acetic acid 1-2% owf
Temp- boil , time -30 min
2. Use of cationic dye fixing agents or
other fastness improving aftertreatment

17. PROBLEMS IN REACTIVE
Sr .no. defects causes Remedies
1.Shade change/
inconsistent shade
Shade change/
inconsistent shade
1. Residual peroxide,
alkalinity or other
contaminants in the substrate
2. Water hardness
3. Contamination of dyebath
with
calcium, magnesium,
chlorine or
heavy metals
4. Improper use of dyebath
assistants, e.g. surfactants,
sequestrants, fixatives,
lubricating
agents
1. Substrate free from
contamination before
dyeing
2. Use of soft water or
appropriate
sequestrants
3. Use of appropriate
sequestrants
4. Use of compatible
dyebath
assistants
2. Poor colour yield Poor colour yield 1. Poor pre-treatment
2. Residual peroxide in the
substrate
3. Dye hydrolysis (only in
case
of reactive dyes)
1. Good pre-treatment
2. No residual peroxide in
the
substrate
3a. Careful storage of dyes
3b. Use of freshly prepared
dye
solution

18. PROBLEM IN VAT DYEING
defects causes Remedies
Poor levelling/uneven
dyeing
1. Low dye diffusion
2. High dye affinity
3. Dyes of poor migration
4. Over reduction of the dye
.5 Low liquor flow rate
6. Poor rinsing before
oxidation
7. Uneven washing/soaping
after-treatments.
1. Use of dyes of good diffusion
2. Use of dyes of optimum
affinity
3. Use of dyes of good
migration
4. Use of sodium nitrite to avoid over
reduction of the dye
5. Optimum liquor flow rate
6. Thorough rinsing before
oxidation
7. Thorough and uniform
washing/soaping after treatments.
Premature oxidation 1. Presence of air inside the
Machine.
2. Insufficient amount of
sodium
dithionite and/or alkali
1. Prevention of air inside the
Machine.
2. Optimum amount of sodium
dithionite and/or alkali

19. cause reason remedie
Oxidation patch in vat
dyeing
Improper oxidation - Sodium bicarbonate
rinsing after after dyeing &
prior to oxidation
Poor rubbing fastness 1. Dyes of poor rubbing
fastness
2. Catalytic damage of the
material
3. Presence of polyvalent
ions
4. Too high moisture in the
test
material
5. Improper use of finishing
agent
1. Use dyes of good rubbing
fastness
2. No catalytic damage of
the
material
3. Use of appropriate
complexing
agents
4. Proper conditioning of the
test
material
5. Proper use of finishing
agents

20. Problem Cause remedie
Shade change/
inconsistent shade
1. Residual peroxide,
alkalinity
or other contaminants in
the
substrate
2. Water hardness
3. Contamination of
dyebath with calcium,
magnesium, chlorine or
heavy metals
4. Improper use of
dyebath assistants, e.g.
surfactants,sequestrants,
fixatives, lubricating
agents
1. Substrate free from
contamination before
dyeing
2. Use of soft water or
appropriate sequestrants
3. Use of appropriate
sequestrants
4. Use of compatible
dyebath assistants

21. Other Dyeing Problem
Problem Cause remedie
Specky dyeing. Too much foaming during
padding.
water drop on fabric before or
after padding.
Add defoamer if required
depending on class of dyestuff.
take preventive measures.
maintain the temp. speed &
time .
Patchy dyeing. Insufficient dip in padding
trough
Selection of proper padding
mangle.
Centre to selvedge variation. Uneven wearing out of rolls of
padding mangle.
Temp.gradient from centre to
side of steaming chamber
Check the uniform expression
of padding mangle.
Ensure uniform temp.across
width of steamer.
Tailing effect. Too large size of padding trough. Use narrow & deep trough of
smaller capacity.

22. Patchy Dyeing
Shade Variation Shade Bar

23. Problem in Jigger Dyeing
defects causes Remedies
Dark or light selvedge . Non-uniform batching
on jigger .
Proper batching on
jigger.
Streakiness. Improper function of
tensioning device in
jigger lead to too high
tension to wet state.
Ensure proper
functioning of tension
rollers on jigger.
Face to face variation. Too high batching
tension on jigger.
Ensure correct batching
on jigger.

24. Problems in Jet & Winch Dyeing
Sr
.no.
defects causes Remedies
01
Crow –feet mark
(crush mark).
Improper jet diameter . Use suitable jet depending
on fabric quality.
02 Oil stains . Use wrong type defoamer which
are break in rapid jet dyeing
cause staining problem.
Use self emulsifying type
silicone defoamer.

25. Crush marks Oil Stains

26. Problems in Continuous Dyeing
defects Causes Remedies
Specky dyeing. Too much foaming during padding.
water drop on fabric before or after
padding.
Add defoamer if required depending
on class of dyestuff.
take preventive measures.
maintain the temp. speed & time .
Choke feeding lines. Inferior dye dispersion Improper selection of dyestuff.
Centre to selvedge variation. Uneven wearing out of rolls of
padding mangle.
Check the uniform expression of
padding mangle.
Tailing effect. Too large size of padding trough. Use narrow & deep trough of
smaller capacity.
 Use hydraulic controlled
rollers
Colour dosing system
PLC
Dye stuff stain  Due to improper handeling
 improper mixing of dyes
•Ensure proper housekeeping
Proper mixing of dyes

27. Dye Stain White Spots

28. PRINTING

29. Defect cause by Hanging Thread
Problem Cause remedies
A break in
Pattern of
Printed fabric
caused by
Hanging
Thread
Loose thread
not treammed
well before
Printing
Non mendable

30. MISPRINT
Problem Main Cause Remedies:
MISPRINT
-Design not set
properly
-unequal
pressure
-Screen Design
not
Properly
Engraved
-cloth feed with
uneven
tension
-Check Proper
Feeding of
cloth &
Speed of
m/c
-Ensure proper
engraving
of Design

31. TINTING
Problem Cause Remedies
Tinting
-Uneven
Printing roller &
doctor blade
pressure
-Printing Paste
level not
maintained
-- defective
doctor blade
- Printing table
not proper
-Check viscosity
of Printing Paste
-Check doctor
blade
-Check Screen

32. BLURERD PATCH
-
Problem Cause Remedies
Blurred patch Uncleaned
Doctor blade &
printing roller
-Doctor blade
not properly
aligned
cleaned Doctor
blade & printing
roller
-Doctor blade
properly aligned

33. WATER MARK
Problem Cause remedies
Water maks
-Contamination
with water prior
to tinting on
padding mangle
-Surface
pressure of one
layer over
another
-Ensure proper
cleaning of
padding mangle
-- ensure
optimum
pressure

34. MISFITS
Problem cause Remedies
Misfits
-Printing screen
Not adjusted
properly
-Improper feed
of fabric
-Faulty engraving
-Proper
adjustment of
screen
-- ensure proper
feed of fabric
use guiders, feed
rollers
-Ensure proper
Engraving acc. To
pattern

35. FLUSHING
Problem Cause remedies
Flushing
-Printed area
bleed into
unprinted
Portion
-Removal of
unfixed print
Do curing at
reqired
temperature

36. SPOTTING
Problem Cause remedies
Spotting
-Unclean
Screen roller
-Spots due to
handling
-Poor uptake
of print paste
-Cleaning of
screen
-Avoid marks
in steaming
-- ensure
proper
squeegee
pressure

37. PRINT COLOUR VARIATION
Problem Cause Remedies
Colour
variation
-Uneven
squeegee
pressure
- Check even
appliation of
pressure
through out
application of
print paste.

38. BLEEDING
Problem Cause Remedies
Bleeding
-Too low viscosity
of color paste
-Too high dyestuff
concentration
Ensure proper
viscosity of Print
paste
- Ensure optimum
concentration of
dyestuff taken

39. STAINING DURING STEAMING
Problem Main cause Remedy:
Staining during
steaming
-Poorly washed
printing Table
-Irregular Steam &
temperature
Ensure Optimum
Temperature while
Steaming for
reactive 102-105ºC

40. SLIGHT TOUCHING
Problem Main Cause Remedies
SLIGHT TOUCHING -Uneven Squeegee
Pressure
-A squeegee with
improper
Hardness
-Improper
viscosity of paste
-Improper use of
thickener
-Optimum
squeegee pressure
-- check squeegee
before use
-Ensure viscosity
of paste
-Proper use of
thickner

41. DOUBLE PRINTING
Problem Main Cause Remedy
Double
printing
-Disfigured
design
-Poor
engraving
-Poor cloth
adhesion
Ensure Proper
engraving

42. PRESSING PASTE BY FRAME
Problem Cause Remedies
Pressing paste
-Poor belt drive
and frame
installation
-Frame mark in
printed area
-Proper frame
installation
over fabric

43. FINISHING

44. STARTING MARKS
Problem Cause Remedies
Staring marks 1. Sudden start, stopped
of machine
2. Squeezing roll not
properly clean
3. At start fabric pass
throgh finishing
chemical & not squeeze
properly
1. Avoid sudden start and
stoppage
2.Squeezig roller clean
3. Ensure proper squeezing
action

45. BOWING
Problem Cause Remedies
Bowing 1. Uneven
tension
during
processin
g
2. Guiders
not
present
1. Maintain
even
tension
Use of Weft
straightn
er
2. Use of
guiders

46. PILLING
Problem Cause Remedies
Pilling
1. Broken
filament
2. Low twist
1. Shearing ,
singeing
2. Ensure
optimum twit

47. PIN HOLES
Problem Cause Remedies
Pin holes
1. Stenter pin 1. Go for clip
for holding
fabric

48. Finishing (Stenter)
Sr .no. defects Causes Remedies
01 Clips cuts and
escape .
Inadequate grey width or reed
space
Mechanical defect in clip bar &
chain rails of the stenter.
Use provide adequate grey width &
reed space with shrinkage expected.
Ensure proper maintenance of clips &
chain rails of stenter.
02
Yellow stains . Overheating & curing of the
finished especially when acid
liberating are used in finish .
Optimum drying & curing condtion
w.r.t time ,temp.
03
Oil dropping &
carbon soot .
Condensation of duct & water , oil
particles
Ensure proper cleaning of stenter
exhaust.
04 Uneven heat
setting.
Variation in parameter Maintain parameter.

49. Calendering (Finishing)
Sr
.no.
defects causes Remedies
01 creases & cut . non-alignment of guide rolls
on calendering m/c giving
rise to crease formation.
Improper stitching of cloth.
Proper selvedge to
selvedge stitching of
material & proper feeding
over well aligned guide
rolls .
02 Dent mark &
stains .
 Dents in the calendering
bow
Filling of dent.& proper
brushing of the bowl .

50. Sanforiser(Finishing)
Sr .no. defects causes Remedies
01 Rubber blanket marks
.
Dent or uneven
surface of the
rubber blanket
.
Ensure proper
and even grinding
of rubber blanket .

51. REFRENCES
• Towards zero Defect Amubhai patel
• www.textilelerner.com
• Major fabric defects during chemical processing
• Quality and Process control S.M. Doshi & HA Shah
• Chemical technology of fibrous materials - F. Sadov
• Technology of Dyeing – V. A. Shenai
• www.kyungin.co.kr/eng/sup/page1.htm#list1
• www.textileinfo.com
• www.alleycatscratch.com
• Critical Solutions In The Dyeing Of Cotton Textile Materials R. Shamey and T. Hussein
• Reduction of values in textile industry,(Bombay textile research ass.nov.14 1983) p-23-38.

52. THANK YOU