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DY E I N G

FAU LT S &
REMEDIES

THEIR

DYEING FAULTS :
The faults which are visible after dyeing are called Dyeing
faults . These faults descries the quality of the fabrics . So to overcome from
this faults we have to know the causes and the remedies of these dyeing
faults .

TYPES OF FAULTS
Dyeing faults can be described on the following basic things
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ii.
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v.

Unlevelness(due to dyeing conditions)


Ending problems
Cloudy dyeing
Pale areas
Unlevelness(due to material)
Barriness
Unlevelness(due to other reasons)
Skitterness
Listing
Pale areas after dyeing
Reproducibility
Deviation of shade
Dyeing too pale
Precipitates in the dyebath
Change of shade
Fastness properties
Unexpectedly poor light fastness
Unexpectedly poor wet and rub fastness
Spots, marks
Precipitates in the dyebath
Singeing droplets
Change of shade (e.g. blue spots in brilliant red shades)
Dark spots
Specks

vi.
7.
i.
ii.
iii.
iv.
v.
vi.
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viii.
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ii.
iii.
iv.
9.
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ii.
iii.
iv.
v.
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viii.
ix.

Dirt spots
Appearance of the goods
Dimensional stability (shrinkage)
Creasing
Chafe marks
Stitch distortion (knits)
Moire effects (on beam)
Lustre
Handle
Pilling (staple fibres)
Other problems
Difficulty with heavy shades on fine denier yarn
Soiling of machine
Frosting on goods
Poor running of material in subsequent processing
Thermosol dyeing problems
Listing
Two-sidedness
Dark or pale selvedges
Barry dyeings
Spots, specks
Ending
Pale points of intersection
Foam formation
Frosting

CAUSES & REMEDIES OF FAULTS

1. Unevenness(due to dyeing conditions)


Ending Problems

Causes

Remedies

- unstable dye dispersion

- select dyes with better dispersion stability, use


efficient dispersants

- unsuitable dye combination

pay attention to uniform dye behavior

- wrong dyeing program

- Optimum dyeing process


Optimizing a dyeing process means adjusting
the process parameters in such a way that the
entire operation takes place in the shortest
possible time without exceeding the tolerance
limits with regard to reproducibility and
levelness. This means rapid heating in the
temperature ranges in which the dye exhausts

slowly or is already exhausted; controlled


heating when the dye exhibits a particularly high
rate of exhaustion.
2. Cloudy dyeing
Causes

Remedies

- inadequate pretreatment

- select optimum conditions and chemicals

- channeling due to irregular winding

- pay particular attention to winding of the material

- poor circulation of the goods due to


interruptions, knots, etc.

- adjust the machine more carefully

- too much foam in the dyebath

- use antifoamers, e.g. Antimussol brands

3. Pale areas

Causes

Remedies

- inadequate pretreatment

- select optimum conditions and chemicals

- air pockets in the material


(e.g. cheeses)

- use special chemicals, e.g. wetting agent / defoamer


combinations, or greater pressure

2. Unlevelness(due to material)
1. Barriness
Causes

Remedies

- variations in temperature during fibre - adapt dye selection


manufacture(texturizing), draft
- select higher dyeing temperature
differences
- select suitable carriers and chemicals
- possibly set fibres at a higher temperature (Caution!)
- variations in the density of the
material (weaving, knitting)

- relax material thoroughly

3. Unevenness(due to other reasons)


1. Skitterness
Causes

Remedies

- inadequate pretreatment
(e.g. desizing)
- fibres of different origins in the
material

- pay attention to perfect pretreatment


- pay particular attention to the appropriate dyeing
process and program

- inadequate penetration
(paler points of intersection)
- poorer solidity on both components
of fibre blends
- irregular thread tension during
weaving or warp knitting
2. Listing
Causes

Remedies

- inconsistent setting temperature

- select special dyes (small-molecule)

- irregular tension in the material due


to weaving or warp knitting

- relax material thoroughly

- poorly wound material

- pay particular attention to winding

- rolled in selvedges due to irregular


- set the goods
tension in the material (weaving, warp - size the selvedges
knitting)
- check the weaving or knitting machine
3. Pale areas after dyeing
Causes
- effect of aggressive vapors
(e.g. acid, chlorite, formaldehyde)

Remedies
- efficient ventilation of vapors and gases
- avoid contact with dangerous substances

4. Reproducibility
1. Deviation of shade
Causes

Remedies

- dye sensitivity to hydrolysis,


reduction, electrolyte

- select dyes carefully, control pH exactly


(buffer system)
- pay attention to stability of dye to electrolytes

- dye sensitivity to metal ions in the


dyebath

- use suitable sequestering agent

- dyes of different chemical

- pay particular attention to selection of dyes and

constitution affect each ocher (rare)

chemicals

- dye buildup affected by chemicals


(retarding effect)

- carry out lab tests

- different dyeing programs

- pay attention to consistent dyeing conditions

- different liquor ratios


- dye shows differences in standard
conformity

- check supplies

- unsuitable dye combination

- pay attention to behaviour of individual elements

- sedimentation of liquid dyes

- stir before removal from container

- bath exhaustion affected by reserve


of adjacent fibre

- adapt dye selection and process

2. Dyeing too pale


Causes
- different buildup of dye on
different materials

Remedies
- carry out preliminary tests with material

3. Precipitates in the
dyebath
Causes

Remedies

- chemicals affect each other's - pay attention to chemical selection


action
- dyeing produced at too low
temperature

- check and adjust dyeing conditions

- dyeing time too short


- unstable chemicals

- pay attention to chemical selection


4. Change of shade

Causes

Remedies

-unfinished diffusion due to insufficient - check and adjust dyeing conditions


dyeing time at too low temperature
- inadequate sublimation fastness of
dye

- pay attention to dye selection

5. Fastness properties
1. Unexpectedly poor light fastness
Causes

Remedies

- carrier residues on fabric


(inadequate thermofixation)

- repeat thermofixation (at higher temperature)

- stained adjacent fibre

- adapt dyeing process, select appropriate dyes

- catalytic fading due to unsuitable dye


combination

- adjust dye selection

2. Unexpectedly poor wet and rub fastness


Causes

Remedies

- thermomigration due to finishing and - adjust dye and chemical selection


softening chemicals
- inadequate dye fixation due to too
short dyeing time or too low fixation
temperature

- optimize dyeing process, reduction clear

- stained adjacent fibre

- improve dyeing process

6. Spots, marks
1. Precipitates in the dyebath
Causes
- dye precipitates due to
poordispersion or dyes with poor
dispersion stability

Remedies
- pay special attention to dispersing instructions
- pay attention to dye selection (dispersion stability)
- use dispersants

- dye crystallization due to variations in - pay attention to perfect liquor circulation


temperature in the dyebath
- coloured spots due to dye deposits
on the machine

- pay attention to cleanness in the machine

- use of volatile carriers

- select suitable carriers, use overhead heating in the


machine

- silicones in the dyebath

- use silicone-free defoamers

- unstable chemicals

- select suitable chemicals

- oil and spinning preparations

- thorough pretreatment

- oligomers in the dyebath

- drop dyebath hot, shorter dyeing time, use special


chemicals

2. Singeing droplets
Causes

Remedies

- as a result of singeing before - singe after dyeing


dyeing, fibre tips exhibit
higher affinity for dyes

3. Change of shade (e.g. blue spots in brilliant red shades)

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