Presentation Topic: "Fabric Defects. Its Causes & Remedies." Presented By: Asif-Al-Jaman Institute: Chattogram BGMEA Institute of Fashion & Technology (CBIFT) Dept.: Apparel Manufacture & Technology (AMT)

1. Name : Asif-Al-Jaman
ID : 171-016-45
Dept : AMT
Semester : 7th
Course Title : Quality Control Management.
Course Code : BUS 411
Welcome to my Presentation on-
“Fabric Defects. Its Causes & Remedies.”

2. CONTENTS
1. Definition of Fabric Defect.
2. Importance of fabric defect identification.
3. Major defects found in woven fabric.
4. Major defects found in knitted fabric.
5. Major defects found in dyed & printed fabric.
6. Dyed fabric defects
 Uneven dyeing
 Running Shade
 Crease Mark
7. Printed fabric defects
 Off printing or misprint
 Uneven print
 Water Mark

3. What is Fabric Defect?
Fabric defect : Defect is any fault that spoils the
material. But, A Fabric Defect is any abnormality in
the Fabric that hinders its acceptability by the
consumer.
There are numerous fabric defects & most of them are
caused by machine or process malfunctions.

4. 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

5. 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.
 Miss pick.
 Wrong end color
 Double pick.
 Weft bar.
 Ball
 Hole etc…

6. 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:
o If stretches or looseness is applied on the picks yarn the
bad selvedges is occurred.
o If the temple is not properly used during weaving.
o Loose or Tight selvedge yarn in the Beam.
Remedies: During weaving loom operator should be careful
on the issues.

7. Broken Ends or Warp
A defect in the woven fabric caused by a warp yarn that was
broken during weaving or finishing.
Reason:
o Poor preparation
o Weak or irregular yarn
o Excessive warp tension
o 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.

8. Broken Pics or Weft
A filling yarn that is broken in the weaving of
fabric
Reason:
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.

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

10. Loose Weft or Snarl
It is produced in woven fabric due to the looseness
of filling yarn.
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.

11. Double Ends
This kind of fault is produced in woven fabric when
the two ends of warp sticks get together after sizing.
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 head
eye and can create this problem.
Remedies:
Worker have to be very careful about this matters

12. 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.
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.

13. 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.
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.

14. 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.
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

15. Major Defects 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 Etc…

16. 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.
Reason:
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
c) 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.

17. 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.
Reason:
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.

18. Contaminations
When foreign matter like dead or dyed fibres or husk, etc
appear in the fabric.
Reason:
• Caused due to the Presence of Dead fibers or other foreign
elements being present in the staple spun yarn like dyed
fibres or husk etc.
• Sometimes adjacent machine’s fibres can fly to the fabric &
get embedded in it.
Remedies:
 Using yarns with rich fibre mixing leads to the occurrence
of a lesser number no. of dead fibres in the fabric.
 In the blow room, tight control in cotton mixing needs to be
ensured to prevent any foreign matter mixing. Also,
portioning machine specially spinning & knitting with
plastic curtains can prevent contamination.

19. 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.
Reason:
• 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.

20. 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.
Reason:
 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

21. Horizontal Stripes
These are caused by unevenness in the courses; they traverse
horizontally and repeat themselves regularly or irregularly.
Reason:
• 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.
• 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

22. Barriness
Barriness defect appears in the knitted fabric in the form of horizontal
stripes of uniform or variable width. Actually barreiness is the periodic
lateral irregularities
Reason:
• Individual yarns differ with respect to count, properties or structure;
• Different course lengths in feeders.
• Knitting of yarns which differ in color;
• 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.

23. Dyed & Printed Fabric Defects
The following dyed & printed fabric
defects are found in fabric
production:
 Bleeding
 Crocking
 Shade Bar
 Off Shade
 Uneven Dyeing
 Batch to batch shade variation
 Patchy Dyeing Effect
 Flushing
 Wicking
 Misfits
 Banding etc…

24. Uneven Dyeing
Reason:
•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

25. Running Shade
Reason:
 Machine loading is higher.
 Running at lower nozzle pressure.
 High bath draining temperature.
Remedies:
• Proper cycle time should be
ensured.
• Nozzle pressure should be
accurate.
• Bath draining temperature should
be moderate.

26. Crease Mark
Reason:
• Excessive loading of fabric during dyeing.
• Sudden change in temperature during cooling.
• Due to lack of synchronization of winch speed
and pump pressure.
Remedies:
• Follow the temperature gradation during
the whole cycle of dyeing.
• Fabric must be loaded according to loop
length.
• Maintaining the proper synchronization
between the winch speed and pump
pressure.

27. Off Printing
Reason:
•Wrong dyeing recipe
•Wrong leveling agent
•Incorrect dye combinations in lots
•Improper scouring of grey fabric
Remedies:
 Implementing uniform dyeing, leveling and scouring
processes can help prevent misprinting.
 If you’re sourcing a printed fabric, make sure to
provide clear specifications regarding the colors and
patterns of your printed fabric to your factory.
Consider providing pantone color numbers and
design files as a guide for your supplier.

28. Uneven Print
Reason:
 Uneven Pressure application on the Printing Rollers.
 Uneven central drum lapping in the machine.
 Uneven diameter of the printing roller.
 Use of defective printing table.
Remedies:
 Ensure proper even pressure on the printing
rollers & the doctor blade.
 Choose even printing surface of the table.
 Central drum lapping should be set evenly.
 Ensure the printing roller’s dimension is even
throughout.

29. Water Mark
Ripple effect in the print.
Reason:
 Improper grey fabric scouring.
 Surface pressure between layers.
Remedies:
 Ensure proper scouring to make sure there are no
impurities.
 Prevent surface pressure between layers.
 Prevent contamination with water on the padding
mangle, which leads to reduce dye liquor
concentration.

30. Thank
You 