Yarn Defects

Some of the common defects are:

1. Thin spots
2. Slubs
3. Fishes
4. Traveller/cracker
5. Spun in
6. Piecing
7. Nep

1. Slubs

EFFECT
 More end breaks in the next process.
 Damaged fabric appearance.
 Shade variation in dyed fabrics.
CAUSES
 Accumulation of fly and fluff on the machine parts.
 Poor carding.
 Defective ring frame drafting and bad piecing.
 Improperly clothed top roller clearers.
RECTIFICATION
 Machine surfaces to be maintained clean.
 Proper functioning of roller clearers to be ensured.
 Broken teeth gear wheel to be avoided and proper meshing to be ensured.
 Better fiber individualization at cards to be achieved.
 Optimum top roller pressure &back zone
 Setting at ring frame to be maintained.

2. Neps

EFFECT
 Damaged fabric appearance
 Shade variation in the dyed fabrics
CAUSES
 Accumulation of fly and fluff on the machine parts
 Poor carding.
 Defective ring frame drafting and bad piecing
 Improperly clothed top roller clearers.
RECTIFICATION
 Machine surfaces to be maintained clean.
 Proper functioning of roller clearers to be ensured.
 Broken teeth gear wheel to be avoided and proper meshing to be ensured.
 Better fiber individualization at cards to be achieved.

3. Snarl

EFFECT
 Entanglement with adjacent ends causing a break
 Damaged fabric appearance
 Shade variation in dyed fabrics
  Improper meshing of gear wheels
 Mixing of cottons varying widely in fiber lengths and use of immature cottons
CAUSES
 Higher than normal twist in the yarn
 Presence of too many long thin places in the yarn
RECTIFICATION
 Optimum twist to be used for the type of cotton processed
 Drafting parameters to minimize thin places in the yarn to be adopted
 The yarn to be conditioned
 Correct tension weights and slub catcher settings to be employed at winding

4. Thick and thin places

EFFECT
 Eccentric top and bottom rollers
 Insufficient pressure on top rollers
CAUSES
 Worn and old aprons and improper apron spacing
 Improper meshing of gear wheels
 Mixing of cottons varying widely in fibre lengths and use of immature cottons
RECTIFICATION
 Eccentric top and bottom rollers to be avoided
 Top arm pressure checking schedules to be Maintained strictly
 Wide variation in the properties of cottons used in the mixing to be avoided
 Better fiber individualization at cards to be achieved.
 Correct spacers to be utilized

5. Soft Yarns

EFFECT:
 More end breaks in subsequent processes
 Shade variation in dyed fabrics
CAUSES:
 Slack tapes dirty jockey pulleys
 Improper bobbin feed on the spools
 Less twist in the yarn
 Bad clearing at the traveler
RECTIFICATION:
 Vibration of bobbins on the spindles to be avoided
 Proper yarn clearing to be ensured
 Periodic replacement of worn rings and travelers to be effected

6. Oil Stained Yarns

EFFECT
 Damaged fabric appearance
 Occurrence of black spot in fabric
CAUSES
 Careless oil in the moving parts, over head pulleys etc
 Piecing made with oily or dirty fingers
 Careless material handlings
RECTIFICATION
 Appropriate material handling procedures to be followed
  Oilers to trained in proper method of lubrication
 Clean containers to be utilized for material transportation

7. Crackers

EFFECT
 More breaks in winding
 More noticeable in polyester and cotton blended yarns
CAUSES
 Mixing of cottons of widely differing staple length
 Closer roller settings
 Eccentric top and bottom rollers
 Non optimum temperature and relative humidity in the spinning shed
 Over spinning of cottons
RECTIFICATION
 Optimum top roller pressure to be maintained
 Mixing of cottons varying widely in fibre length to be avoided
 Use of optimum roller settings
 Use of properly buffed rollers free from eccentricity to be ensured

8. Bad Piecing

EFFECT
 More end breaks in subsequent process
 Increase in hard waste
CAUSES
 Wrong method of piecing and over end piecing
 Twisting the ends instead of knotting
RECTIFICATION
 Tenters to be trained in proper methods of piecing
 Separators to be provided
 Excessive end breaks in spinning to be avoided

9. Oily Slubs
EFFECT
 More end breaks in the ensuring process
 Damaged fabric appearance
 Shade variation in dyed fabrics
CAUSES
 Accumulation of oily fluff on machinery parts
 Poor methods of lubrication in preparatory processes
 Negligence in segregating the oily waste from process waste
RECTIFICATION
 Yarn contact surfaces to be kept clean
 Oilers to be trained in correct procedures of lubrication
 Proper segregation of oily waste from process waste
10. Kitty Yarns
EFFECT
 Damaged fabric appearance
 Production of specks during dyeing
 Needle breaks during knitting
 Poor performance during winding
 CAUSES
 Ineffective cleaning in Blow room and cards
 Use of cottons with high trash and too many seed coat fragments
RECTIFICATION
 Cleaning efficiency of blow room and cards to be improved
Optimum humidity in the departments to be ensured

11. Hairiness
EFFECT
 More end breaks in winding
 Uneven fabric surface
 Beads formation in the fabric in the case of polyester/cotton blends
CAUSES
 Use of cottons differing widely in the properties in the same mixing
 Use of worn rings and lighter travelers
 Maintaining low relative humidity, closer roller settings and very high spindle speeds
RECTIFICATION
 Use of travelers of correct size and shape and rings in good condition to be ensured Periodic
replacement of travelers and suitable
 Roller settings to be maintained
 Optimum relative humidity to be maintained in the spinning room
 Wide variation in the properties of cottons used in the mixing to be avoided

12. Foreign Matters

EFFECT
 Breaks during winding
 Formation of holes and stains in cloth
 Damaged fabric appearance
CAUSES
 Improper handling of travelers
 Improper preparation of mixings
RECTIFICATION
 Removal of foreign matters(such as jute fibres, color cloth bits) to be ensured during
preparation of mixing
 Installation of permanent magnets at proper
 Places in blow room lines to be ensured

13. Spun in fly

EFFECT
 More breaks in winding
CAUSES
 Accumulation of fluff over machine parts
 Fanning by workers
 Failure of over head cleaners
 Malfunctioning of humidification plant
RECTIFICATION
 Machinery surfaces to be kept clean by using roller pickers
 Fanning by workers to be avoided
 Performance of over head cleaners and humidification plants to be closely monitored
14. Cork Screw Yarns

EFFECT
 Breaks during winding
 Causes streaks in the fabric
CAUSES
 Feeding of two ends (instead of one ) in ring frame
 Lashing -in ends in ring frame
RECTIFICATION
 Tenters are to be trained in piecing methods(or) practices
 Pneumafil ducts to be kept clean and properly set

15. Slough Off

EFFECT
 Increase in end breaks
 Higher yarn waste
CAUSES
 Improper ring rail movement
 Worn builder cam
 Loose package and excessive coils in the package
 Improper empties fit on the spindles and slack tapes
RECTIFICATION
 Ring rail movement to be set right
 Optimum ratio of winding: bindings coils and optimum chase length to be maintained

16. Ring cuts

EFFECT
 Excessive breaks during winding
 More hard waste at winding
CAUSES
 Spindle or empty cops wobbling
 Use of lighter travelers and incorrect ratchet wheel
 Movement of spindles to the rings not concentric
RECTIFICATION
 Worn spindles to be replaced
 Improper fit of empty cops with spindles to be avoided
 Gauging of spindles with rings to be properly carried out
 Use of right type traveler and ratchet wheel to be ensured

17. Improper bobbin build

EFFECT
 Slough-off during doffing/winding
 More breaks during unwinding (due to slough off)
 Higher hard waste in winding
CAUSES
 Improper combination of ratchet and pawl
 Jerky ring rail movement(proper rod movement to check)
RECTIFICATION
 Ratchet and Ratchet/pawl movement to be accurately arrived at taking into consideration
 Count of yarn, ring dia and chase length to be taken care off
18. Stitching on Cone

EFFECT
 More end breaks in the subsequent process
 Excessive yarn waste
CAUSES
 Vibrating and wrongly set cone holder
 Yarn coils wrapped round the base of cone holder
 Traverse restrictors fixed at incorrect position
 Improper alignment of tension brackets with the drum
RECTIFICATION
 Maintenance cone winders to be good
 Cone holder settings and alignment of tension
 Brackets with drum to be carried out as frequently as possible

19. Ribbon wound cone

EFFECT
 High level of slough off during unwinding
 Excessive yarn waste
 Uneven dye pick up in the case of dye packages
CAUSES
 Winding spindle not revolving freely
 Cone holders incorrectly set
 Defective settings of cam switch
 Lint accumulation in builder cam groove
RECTIFICATION
 Over hauling of cone winders to be periodically carried out
 Anti ribboning mechanism to be checked at frequent interval
 Free movement of the cone holders to be ensured by proper lubrication

20. Soft build cone

EFFECT
 Overall density of package is lower
 Soft packing either at the base or at the nose of cones
CAUSES
 Improper alignment of winding spindle to the winding drum
 Insufficient unwinding tension
 Inadequate cradle loading
RECTIFICATION
 Unwinding tension to be maintained at 6 to 8% of single yarn
 Strength Cradle pressure to be maintained to the optimum level

21. Bell Shaped cone

EFFECT
 Excessive breaks during subsequent processes
CAUSES
 High yarn tension during winding
 Cone holders incorrectly set to the winding drum
 Damages in paper cone centre
 RECTIFICATION
 Quality of cones to be checked at that time of procurement
 Optimum unwinding tension to be maintained

22. Nose Bulging

EFFECT
 Slough during warping/unwinding
 Excessive yarn waste in next process
CAUSES
 Improper setting of cone holders to the winding drum
 Damaged nose of the paper cones
RECTIFICATION
 Periodical inspection of settings in winding machines
 Tenters to be instructed to adopt correct work practices
 Avoiding usage of damaged paper cones

23. Collapsed cone

EFFECT
 Use of poor quality /damaged paper cones
 Poor system of material handling
 Maintaining non optimum unwinding tension
CAUSES
 Use of poor quality/damaged cones
RECTIFICATION
 Using of poor quality/damaged paper cones should be avoided
 Winding tenters should be trained by proper work methods
 Proper material handling devices such as cone transport trolleys to be used
 Cone inserts to be used for paper cones