Fundamentals of denim & faults in rope dyeing

S outhe as t Unive rs ityDepartment of Textile Engineering Fundamentals of 14/09/2011... S outhe as t Unive rs ityDepartment of Textile Engineering  Typical denim fabrics are woven fro

S outhe as t Unive rs ity

Department of Textile Engineering

Fundamentals of

14/09/2011

Name : MAZADUL HASAN SHESHIR

ID: 2010000400008

Batch: 13th Batch (Session 2009-2013) Department: Wet Processing Technology Email: mazadulhasan@yahoo.com

Blog: www Textilelab.blogspot.com

Southeast University

Department of Textile Engineering

PREPARED BY © right

S outhe as t Unive rs ity

Department of Textile Engineering

 To know about fault of each process

 To know what is the cause of this faults

 To know about remedies of each faults

 Quality improvement of the product

 Fault analysis.

Objective of t he project:

Fundamentals of Denim & Faults in Rope Dyeing

S outhe as t Unive rs ity

Department of Textile Engineering

 Typical denim fabrics are woven from coarse

indigo dyed cotton yarn

 They are hard weaving high density fabrics with a

high mass per unit area

 Denim is produced more in the world than any other

type of cloth

 It is made for a variety of application and in a wide

range of qualities and shades

 Even today, classic denim is still dyed with indigo

 It is a special process in which only the surface of

the warp yarn is dyed & the weft stays white.

 This is why the garment subsequently develops

the typical and desired signs of wear.

What is Denim ?

14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing

S outhe as t Unive rs ity

Department of Textile Engineering

 Drivability -excellent

 Luster good

 Texture -cotton, thus excellent for clothing

 Absorbency excellent Looks good wet, clings

 Durability excellent Stands up to heavy wear and abuse

 Resilience excellent Tough fabric, stands up to washing

 Flammability Can be treated to be less flammable, but is cotton

 Fabric source Cotton

Examples of end use -jeans, skirts, shirts, jackets Most popular

clothing material in the world.

14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing

The properties of denim are as follows :

S outhe as t Unive rs ity

Department of Textile Engineering

1 Stone washed

a) Single stone washed b).Double stone washed

2 Chambray

3 Fancy with multi color denim

4 Denim with metal effect

5 Elastic denim

6 Printed denim

7 Jacquard patterned denim

8 Denim with fancy yarns

14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing

Denim can be classified as follows :

S outhe as t Unive rs ity

Department of Textile Engineering

Mostly use type of Denim Fabric

14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing

Type of Denim dyeing process :

 Indigo rope dyeing process

 Indigo one sheet dye slashing

 Indigo double sheet dyeing

 Loop dye 1 for 6 (continuous dye slashing)

 Loop dye 1 for 6 with dyemer (continuous

mercerization dyeing and sizing).

S outhe as t Unive rs ity

Department of Textile Engineering

Deference between slasher dyeing vs rope dyeing :

Slasher Dyeing Rope Dyeing

1 Required less floor space 1 Required more floor space

2 It is a continuous process 2 It is not a continuous process

3 The mercerizing process is easy and

simple 3 In Rope dyeing mercerizing is difficult

4 Required less manpower 4 Required more man power

5 The capacity of dye bath is 100 liter 5 The capacity of dye bath is 2500

liter

S outhe as t Unive rs ity

Department of Textile Engineering

Flow chart of denim fabric procedure:

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Department of Textile Engineering

Faults in warping:

Fundamentals of Denim & Faults in Rope

Dyeing

1 Lot variation 1 Several lot yarn come

from spinning mill 1 Yarn cone must be tested before production

2 Chain breakages 2 Irregular maintenance

of chain spoke & gear 2 Proper maintenance & lubrication

of the chain gear and spoke

3 Thermal damages 3 Improper lubrication 3 frictional dnun should not be

kept in a polished state

S outhe as t Unive rs ity

Department of Textile Engineering

Fundamentals of Denim & Faults in Rope Dyeing

4 Sprockets are

not work properly

4 Proper lubrication must be done

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Department of Textile Engineering

Fundamentals of Denim & Faults in Rope Dyeing

1 Leakage of steam in

drying cylinders 1 Not proper working the steam valve 1 Proper maintenance has to done of the pressure valve

2 Wear and tear of rollers 2 If bearing is jamed 2 Lubricant have to use

3 Entanglement of rope 3 Improper working

of load cell oil squeezing roller

3 Pressure has to distribute properly

Dyeing faults:

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Department of Textile Engineering

Fundamentals of Denim & Faults in Rope Dyeing

4 Shade variation 4 Faults in dosing

system 4 Dosing pump,filter, outer have to

maintenance properly

5 Broken yarn in tile

rope 5 Improper alignment of the yarn in the

rope

5 Change the pressure of theguide roller

6 Irregular rope 6 Improper alignment

of the rope 6 Guide roller has to work properly.

Continue:

S outhe as t Unive rs ity

Department of Textile Engineering

Fundamentals of Denim & Faults in Rope Dyeing

1 Pressure rollers do

not work properly 1 Incorrect shaft adjustment, whipe

roller covering, shed closure wrong

1 Shaft adjustment ,Whipe roller covering have to done properly

2 Squeezing rollers do

not work properly 2 Incorrect shaft adjustment 2 Shaft adjustment have to check Properly

3 Size dust-off 3 Size chemicals are not

properly mixed

3 Size box have to accommodate in

a Proper condition

Faults in sizing:

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Department of Textile Engineering

Fundamentals of Denim & Faults in Rope Dyeing

2 Air pressure of all nozzles

WEFT PATTI 1 Piston is not working properly

2 Missing gear of slippage of pinion

1 Check piston

2 Check beam gear and beam drive pinion

Faults in Weaving:

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Department of Textile Engineering

Fig: Bent Pick Fig: Weft Patti

Fig: Weft Float Fig: Missing End

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Department of Textile Engineering

WEFT FLOAT 1 Air pressure Variation2 Damage of air pipe 1 Check Air pressure2 Check leakage of air pipes

MISSING END

1 Serrated bars are loose contact

2 Dropper sensitivity is not working properly

1 Check all serrated bars are not in loose contact at the clamp

2 Dropper sensitivity to be checked

1 Check warp tension

2 Check that temple cover is face to face with temple bracket

Continue

S outhe as t Unive rs ity

Department of Textile Engineering

Fig: Torn or Hole at the Temple

Fig: Missing Pick Fig: Tight Ends

Fig: Abrasion Mark

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Department of Textile Engineering

ABRASION MARK 1 Cross end problem

2 Tight heald wires

1 Check cross ends

2 Check freeness of heald wires

MISSING

PICK

1 Wrong feeler timing in board

I-2 Unsufficient air pressure

1 Check feeler timing in I-board

2 Check setting of FU

TIGHT ENDS 1 Unparallel warp yarn

2 Entangle warp yarn

1 Check that ends should be parallel

2 Remove entanglement of warp ends

Continue

S outhe as t Unive rs ity

Department of Textile Engineering

OIL DAGHI 1 Oily fluff stuck on the warp sheet

2 Oily fluff on the emery roll

1 Check that no oily fluff is stuck to the warp sheet

2 Check that no oily fluff is stuck to the emery roll or pressure roll

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Department of Textile Engineering

Fig: Oily Warp Fig: Ball Formation

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Department of Textile Engineering

Remark

 In this experiment we learn more think about the denim dyeing process

 It is very helpful our next life to work in the denim dyeing unit

 At lest thank to our respected Course teacher to give me the opportunity to work this type of wonderful experiment

14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing

Reference:

 Understanding Textile for a Merchandiser

 Envoy Textile Ltd

 www.scribd.com