Reteta Gososari

Dyeing Problems Page 1 of 22
1. Unlevelness(due to dyeing conditions)

i. Ending problems
ii. Cloudy dyeing
iii. Pale areas
2. Unlevelness(due to material)
i. Barriness
3. Unlevelness(due to other reasons)
i. Skitterness
ii. Listing
iii. Pale areas after dyeing
4. Reproducibility
i. Deviation of shade
ii. Dyeing too pale
iii. Precipitates in the dyebath
iv. Change of shade
5. Fastness properties
i. Unexpectedly poor light fastness
ii. Unexpectedly poor wet and rub fastness
6. Spots, marks
i. Precipitates in the dyebath
ii. Singeing droplets
iii. Change of shade (e.g. blue spots in brilliant red shades)
iv. Dark spots
v. Specks
vi. Dirt spots
7. Appearance of the goods
i. Dimensional stability (shrinkage)
ii. Creasing
iii. Chafe marks
iv. Stitch distortion (knits)
v. Moire effects (on beam)
vi. Lustre
vii. Handle
viii. Pilling (staple fibres)
8. Other problems
http://www.kyungin.co.kr/eng/sup/page1.htm 13.09.2016
i. Difficulty with heavy shades on fine denier yarn

ii. Soiling of machine
iii. Frosting on goods
iv. Poor running of material in subsequent processing
9. Thermosol dyeing problems
i. Listing
ii. Two-sidedness
iii. Dark or pale selvedges
iv. Barry dyeings
v. Spots, specks
vi. Ending
vii. Pale points of intersection
viii. Foam formation
ix. Frosting
1. Unlevelness(due to dyeing conditions)
1. Ending Problems | Unlevelness (Dyeing condition) | All List |
Causes Countermeasures
- unstable dye dispersion - select dyes with better dispersion stability,use

efficient dispersants
- unsuitable dye combination - pay attention to uniform dye behaviour
- 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. The individual steps for an optimum

dyeing process are;
heat at the maximum rate to the threshold of

the critical temperature range T1(PhaseA)
control the rate of heating in the critical
temperature range T1-T2(Phase B)
on reaching T2(upper limit of the critical
temperature range)heat again at the
maximum rate to the fixation temperature
(Phase C).
2. Cloudy dyeings | Unlevelness (Dyeing condition) | All List |
- inadequate pretreatment - select optimum conditions and chemicals
- channeling due to irregular winding - pay particular attention to winding of the material
-wrong loading of the machine or - see above

bobbins(too much material, too tight
winding, etc.)
- poor circulation of the goods due to - adjust the machine more carefully
interruptions, knots, etc.
- too much foam in the dyebath - use antifoamers, e.g. Antimussol brands
- wrong dyeing programme - Optimum dyeing process

(heating, pressure, speed) 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. The individual steps for an optimum
dyeing process are;
heat at the maximum rate to the threshold of

the critical temperature range T1(PhaseA)
control the rate of heating in the critical
temperature range T1-T2(Phase B)
on reaching T2(upper limit of the critical
temperature range)heat again at the
maximum rate to the fixation temperature
(Phase C).
3. Pale areas | Unlevelness (Dyeing condition) | All List |
- inadequate pretreatment - select optimum conditions and chemicals
- air pockets in the material - use special chemicals, e.g. wetting agent /
(e.g. cheeses) defoamer combinations, or greater pressure
2. Unlevelness(due to material)
1. Barriness | Unlevelness (Material) | All List |
- 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 - relax material thoroughly

material (weaving, knitting)
3. Unlevelness(due to other reasons)
1. Skitterness | Unlevelness (Other) | All List |
- inadequate pretreatment - pay attention to perfect pretreatment

(e.g. desizing) - pay particular attention to the appropriate dyeing
process and programme
- fibres of different origins in the

material
- inadequate penetration
(paler points of intersection)
- poorer solidity on both components

of fibre blends
- irregular thread tension during

weaving or warp knitting
2. Listing | Unlevelness (Other) | All List |
- inconsistent setting temperature - select special dyes (small-moleculed)
- irregular tension in the material due - relax material thoroughly

to weaving or warp knitting
- 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 | Unlevelness (Other) | All List |
- effect of aggressive vapours - efficient ventilation of vapours and gases

(e.g. acid, chlorite, formaldehyde) - avoid contact with dangerous substances
4. Reproducibility
1. Deviation of shade | Reproducibility | All List |
- dye sensitivity to hydrolysis, - select dyes carefully, control pH exactly

reduction, electrolyte (buffer system)
- pay attention to stability of dye to electrolytes
- dye sensitivity to metal ions in the - use suitable sequestering agent

dyebath
- dyes of different chemical - pay particular attention to selection of dyes and

constitution affect each ocher (rare) chemicals
- dye buildup affected by chemicals - carry out lab tests

(retarding effect)
- different dyeing programmes - pay attention to consistent dyeing conditions
- different liquor ratios
- dye shows differences in standard - check supplies

conformity
- unsuitable dye combination - pay attention to behaviour of individual elements
- sedimentation of liquid dyes - stir before removal from container
- bath exhaustion affected by reserve - adapt dye selection and process

of adjacent fibre
2. Dyeing too pale | Reproducibility | All List |
- different buildup of dye on different - carry out preliminary tests with material
materials
3. Precipitates in the dyebath | Reproducibility | All List |
- chemicals affect each other's action - pay attention to chemical selection
- dyeing produced at too low - check and adjust dyeing conditions

temperature
- dyeing time too short
- unstable chemicals - pay attention to chemical selection
4. Change of shade | Reproducibility | All List |
-unfinished diffusion due to - check and adjust dyeing conditions

insufficient dyeing time at too low
temperature
- inadequate sublimation fastness of - pay attention to dye selection

dye
5. Fastness properties
1. Unexpectedly poor light fastness | Fastness Properties | All List |
- carrier residues on fabric - repeat thermofixation (at higher temperature)

(inadequate thermofixation)
- stained adjacent fibre - adapt dyeing process, select appropriate dyes
- catalytic fading due to unsuitable - adjust dye selection

dye combination
2. Unexpectedly poor wet and rub fastness | Fastness Properties | All List |
- thermomigration due to finishing and - adjust dye and chemical selection

softening chemicals
- inadequate dye fixation due to too - optimize dyeing process, reduction clear
short dyeing time or too low fixation
temperature
- stained adjacent fibre - improve dyeing process
6. Spots, marks
1. Precipitates in the dyebath | Spots, marks | All List |
- dye precipitates due to - pay special attention to dispersing instructions

poordispersion or dyes with poor - pay attention to dye selection (dispersion stability)
dispersion stability - use dispersants
- dye crystallization due to variations - pay attention to perfect liquor circulation

in temperature in the dyebath
- coloured spots due to dye deposits - pay attention to cleanness in the machine
on 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 | Spots, marks | All List |
- 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) | Spots, marks | All List |
- dye is sensitive to metal ions - use a sequestering agent
- alkali residues - neutralize the goods
- finishing chemicals - scour and select finishing chemicals carefully
4. Dark spots | Spots, marks | All List |
- solvent residues from pretreatment - complete removal of solvents
5. Specks | Spots, marks | All List |
- contamination of the material by - do not store material near dyes; use lowdusting
dyestuff dust dyes
6. Dirt spots | Spots, marks | All List |
- contamination of the material by - pay attention to clean machines and clean working
rust, oil, graphite, etc. methods
7. Appearance of the goods
1. Dimensional stability (shrinkage) | Appearance of the goods | All List |
- insufficient relaxation during - adapt relaxation and setting to material in question

pretreatment
- inadequate setting of material
- lengthwise disortion caused - adjust dyeing machine to material
by dyeing machine
2. Creasing | Appearance of the goods | All List |
- inadequate pretreatment - select optimum pretreatment conditions

(scouring, relaxation, setting)
- due to quality of goods (structure, - adjust dyeing machine to material, select correct
e.g. tightly woven fabric, weight) setting temperature, adjust stenter correctly
- poor suitability of dyeing machine - select more suitable dyeing machine
- too heavy batch of fabric - add a lubricant, e.g. lmacol brand
- incorrect loading of machine
- dyeing process (heating, cooling) - adjust temperature programme, add a lubricant,

e.g. lmacol brand
3. Chafe marks | Appearance of the goods | All List |
-mechanical friction due to - add a lubricant e.g. lmacol brand

overloading
- rough patches in the machine
- stationary material in the running

machine (knots)
- too high machine speed
4. Stitch distortion (knits) | Appearance of the goods | All List |
- inadequate pretreatment - selection optimum pretreatment conditions

(relaxation, setting)
- mechanical effects, e.g. passage of - straight seams along weft and stitches
goods in machine, squint seams
5. Moire effects (on beam) | Appearance of the goods | All List |
- inadequate pretreatment - select suitable setting conditions

(setting, rolling up) - roll up carefully
6. Lustre | Appearance of the goods | All List |
- physical change in fibre due to local - avoid prolonged contact of stationary material with
pressure and high temperature on the hot machine
material
- excessive setting - select suitable setting temperature
7. Handle | Appearance of the goods | All List |
- unfavourable conditions between - select optimum conditions

machine and material
- inadequate pretreatment - can be corrected during finishing

(relaxation, setting)
- wrong dyeing programme

(temperature / time)
8. Pilling (staple fibres) | Appearance of the goods | All List |
- susceptible fibre origin (also in fibre - select fibres carefully, use selected softeners
blends)
- inconsistent dimensional stability - setting

due to shrinkage (fibres protrude from
fibre bundle)
8. Other problems
1. Difficulty with heavy shades on fine denier yarn | Other | All List |
- fibre surface - select suitable dyes
2. Soiling of machine | Other | All List |
3. Frosting on goods | Other | All List |
4. Poor running of material in subsequent processing | Other | All List |
- oligomers
9.Thermosol dyeing problems
1. Listing | Thermosol problems | All List |
- one-sided liquor feed into the trough - check injection pipe or mount a distribution plate
- different nip roller pressure - check rollers (pickup) regularly
- unlevel migration in intermediate - check temperature and air current over the entire
drying width in the drier
- avoid migration by using lowest possible pickup and
a suitable migration inhibitor.
Select dyes with little tendency to migrate.
- uneven thermosolling or fixation of - check fixation units regularly with thermopaper or

dyes due to temperature differences temperature sensors
- use more reliable dyes with as little sensitivity as
possible to temperature deviations
2. Two-sidedness | Thermosol problems | All List |
- deflecting roller touched on one side - check entry of goods, if necessary replace roller
only
- deflecting roller stationary -set roller in motion
- pad rollers not the same - check Shore hardness, if necessary re-cover rollers
- uneven drying from side to side - check temperature and air current in drying
machine
3. Dark or pale selvedges | Thermosol problems | All List |
- one-sided liquor feed into the trough - check liquor feed
- narrow goods impregnated on a - move to a suitable machine

wide padder
- worn rollers, rollers bend due to over - check the nip pressure, reduce pressure if
compensation necessary, change rollers if necessary, chick
hydraulics
- varying drying conditions over the - check the air jets and circulation
width of the goods
- alkali residues in the goods - add acetic acid to the padliquor for pH 5-6
4. Barry dyeings | Thermosol problems | All List |
- uneven jet pressure in the drier - check the air jets
- inadequate evenness of tension in - check guidance of goods in drier

drier, crease formation
- alkali residues in the goods - add acetic acid to padliquor for pH5-6
5. Spots, specks | Thermosol problems | All List |
- pale marks due to condensation - check driers and pad-steam units regularly
drops - overhead heating
- foam spots due to excessive - avoid high turbulence in the padding trough, use
foaming of the pad liquor low-foaming chemicals, if necessary add antifoamers
- coloured specks due to incorrect - follow instructions for preparing the padliquor
preparation of the padliquor exactly, filter padliquor before feeding into trough
- avoid drying out of liquid dyes due to incorrect
storage
- alkali residues in the goods - add acetic acid to padliquor for pH5-6
6. Ending | Thermosol problems | All List |
- dye substantivity - with lndigosol dyes add Lyogen WL

- use a smaller volume of liquor
- dye at higher fabric speed
- dye sedimentation - keep the liquor in motion

- keep the temperature below 35C
7. Pale points of intersection | Thermosol problems | All List |
- poor penetration - add a wetting agent to the padliquor

- change the pressure of the rollers
- increase impregnation time
- severe migration - dry more slowly

- use special migration inhibitors
8. Foam formation | Thermosol problems | All List |
- dispersants in the dye - use antifoamers
- residues of boiling off agent - scour goods better before dyeing
9. Frosting | Thermosol problems | All List |
- migration during thermosolling - use special chemicals
- fibre tips not dyed (e.g. viscose) - add Lyogen V

- change process, e.g. wet steaming

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Dyeing Problems Page 1 of 22

1. Unlevelness(due to dyeing conditions)

i. Difficulty with heavy shades on fine denier yarn

1. Unlevelness(due to dyeing conditions)

1. Ending Problems | Unlevelness (Dyeing condition) | All List |

- unstable dye dispersion - select dyes with better dispersion stability,use

- unsuitable dye combination - pay attention to uniform dye behaviour

- wrong dyeing program - Optimum dyeing process

of exhaustion. The individual steps for an optimum

heat at the maximum rate to the threshold of

2. Cloudy dyeings | Unlevelness (Dyeing condition) | All List |

- inadequate pretreatment - select optimum conditions and chemicals

-wrong loading of the machine or - see above

- wrong dyeing programme - Optimum dyeing process

without exceeding the tolerance limits with regard to

heat at the maximum rate to the threshold of

3. Pale areas | Unlevelness (Dyeing condition) | All List |

- inadequate pretreatment - select optimum conditions and chemicals

1. Barriness | Unlevelness (Material) | All List |

- variations in temperature during fibre - adapt dye selection

- variations in the density of the - relax material thoroughly

3. Unlevelness(due to other reasons)

1. Skitterness | Unlevelness (Other) | All List |

- inadequate pretreatment - pay attention to perfect pretreatment

- fibres of different origins in the

- poorer solidity on both components

- irregular thread tension during

2. Listing | Unlevelness (Other) | All List |

- inconsistent setting temperature - select special dyes (small-moleculed)

- irregular tension in the material due - relax material thoroughly

- poorly wound material - pay particular attention to winding

- rolled in selvedges due to irregular - set the goods

3. Pale areas after dyeing | Unlevelness (Other) | All List |

- effect of aggressive vapours - efficient ventilation of vapours and gases

1. Deviation of shade | Reproducibility | All List |

- dye sensitivity to hydrolysis, - select dyes carefully, control pH exactly

- dye sensitivity to metal ions in the - use suitable sequestering agent

- dyes of different chemical - pay particular attention to selection of dyes and

- dye buildup affected by chemicals - carry out lab tests

- different dyeing programmes - pay attention to consistent dyeing conditions

- different liquor ratios

- dye shows differences in standard - 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 - adapt dye selection and process

2. Dyeing too pale | Reproducibility | All List |

3. Precipitates in the dyebath | Reproducibility | All List |

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

- dyeing produced at too low - check and adjust dyeing conditions

- dyeing time too short

- unstable chemicals - pay attention to chemical selection

4. Change of shade | Reproducibility | All List |

-unfinished diffusion due to - check and adjust dyeing conditions

- inadequate sublimation fastness of - pay attention to dye selection

1. Unexpectedly poor light fastness | Fastness Properties | All List |

- carrier residues on fabric - repeat thermofixation (at higher temperature)

- stained adjacent fibre - adapt dyeing process, select appropriate dyes

- catalytic fading due to unsuitable - adjust dye selection

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

- stained adjacent fibre - improve dyeing process

1. Precipitates in the dyebath | Spots, marks | All List |

- dye precipitates due to - pay special attention to dispersing instructions