ASSIGNMENT ON

KINTTING FABRIC DEFECTS , CAUSES AND

SOLUTIONS

SUBMITTED BY : SUBMITTED TO
ANKUR VERMA Dr. SUBHANKAR
( 1900440620006) MAITY
MMFT
 INTRODUCTION
Identification of faults during manufacturing of knitted fabrics with circular knitting
machine is important for better quality and production. Any faults occurring in the
knitting process needs to be find out and should be corrected. The images of the
knitted fabrics are considered to specify the faults. Knitted fabrics faults can also be
detected by inspecting yarn tension and loop but only some types of faults can be
identified.

FACTORS THAT LEADS TO FABRIC DEFECTS

A. MATERIAL RELATED FACTORS
 Fibre contaminants .
 Excessive neps and seed coat fragments.
 Excessive short fibre content.
 Excessive trash content.
 High variability between and within mix.
 Clusters of unfavourable fibers characteristics.
 Weight variations.
 Twist variations.
 Excessive hairiness.

B. MACHINE RELATED FACTORS

 Failure of spinning preparations to eliminate short and long term variations.
 Failure of the mixing machinery to provide a homogeneous blend.
 Excessive machine stops particularly during spinning.
 Excessive end piecing during spinning preparations.
 Poor maintenance and house keeping.
 Knitted related defects.
 Dyeing and finishing related defects.

DEFECTS DEFINATIO FIGURE CAUSES REMEDIES

N
Drop stitches Small or 1. High tension . 1. Ensure uniform
big holes of 2. Yarn overfeed. tension on all
same or 3. High fabric take down feeders.
different tension. 2. Rate of yarn feed
size. 4. Defects like: slubs , should be regulated
neps and knots. according to
5. Incorrect gap between required stitch
dial and cylinder. length.
3. Gap between dial
and cylinder should
be adjusted
correctly.
4. Yarn used should
should free from
 imperfections.
5. Fabric tube should
not to tight or too
slack.
BARRINESS Horizontal 1. High yarn tension . 1. Keep uniform yarn
stripes of 2. Count variation. tension on all
uniform or 3. Mixing of yarn lots. feeders.
uneven 4. Package hardness 2. Average count
width. variation. variation should not
be more than +3 or -
3.
3. Yarn used should
be of the same lot.
4. Hardness of all
packages should be
uniform.
PIN HOLE 1. Improper tension. 1. Different drive
2. Same drive for knit and have to be
tuck stitch maintained.
3. Curved needles latch. 2. Good quality
needle should use.

STAR MARK 1. Yarn tension variation 1. Maintain same

during production. yarn tension during
2. Buckling of the needle production.
latch. 2. Use good
3. Low GSM fabric conditioned needles.
production.
PATTA 1. Yarn count tension. 1. Proper yarn count
2. Yarn tension variation. and tension should
be maintained.

CONTAMINATIONS 1. Presence of dead fibers 1. Use rich fiber

and other foreign materials.
2. Presence of immature
cotton fibers.
mixing for the yarns.
2. To prevent the
mixing of foreign
matters in cotton
mixing.
3. Segregate the
spinning and knitting
machines.
Broken needles Show 1. High yarn tension. 1. Keep uniform yarn
prominentl 2. Bad setting of the yarn tension on all yarn
y as feeders. feeders.
vertical 3. Old and worn out needle 2. Periodically
lines set. change the complete
parallel to 4. Breakage of hook or but sets of needles.
the wales. in needle. 3. Keep the
5. Cylinder grooves are too recommended gap
tight restricting needle between yarn
movement. feeders and the
needles.
4. Remove fly from
groove.
5. Replace defective
needle.
NEEDLE LINES 1. Bent latches, needle hook 1. Replace all the
and needle stems. defective needles
2. Tight needle in the having bent
grooves. latches,hooks or
3. Wrong needle selection. stems.
2. Remove fibre
accumulated in the
needle tricks.
3. Check the needle
filling sequence in
the cylinder / dial
grooves.
SINKER LINES 1. Bent or worn out sinker. 1. Replace all the
2. Sinkers being tight , in the worn out or bent
sinker ring grooves. sinkers causing
sinker lines in the
fabric.
2. Sinker lines are
very fine and feeble
vertical lines
appearing in the
fabric.
3. Remove the fibers
clogging in the sinker
tricks.
BROKEN ENDS 1. High yarn tension. 1. Keep correct yarn
2. Yarn exhausted on the tension on all the
cones. feeders.
2. Yarn detectors on
all the feeders are
working properly.
3. Keep a skilled and
alert machine
operator.
FABRIC PRESS OFF Big or small 1. End breakages on feeders 1. Needle detectors
holes in with all needles knitting. should be set to
fabric 2. Yarn feeder remaining in detect the closed
lifted up position due to needles and prevent
which yarn does not get the fabric tube from
feed into hooks of needles. pressing off.
2. Proper yarn
tension maintained
on all feeders.
LYCRA OUT AND 1. Breakage of lycra yarn 1. To maintain
TENSION and uneven tension of lycra. uniform yarn
VARIATION OF tension.
LYCRA

SPIRALITY Appears in 1. High yarn tension. 1. Use hosiery yarn

the form of 2. Hosiery yarns are soft of recommended
twisted twisted whereas warp yarns TPM level for
garments are hard twisted. knitting.
after 3. Uneven fabric take down 2. Fabric pull or the
washing. tension. take down tension
4. Unequal rate of fabric on both sides of the
feed on stenter , calender ,
grey fabric tube on
and compactor machines. the knitting machine
should be equal.
3. Keep uniform feed
rate of fabric.
OIL LINES 1. Fibers accumulated in 1. Remove all
needle tricks which remain needles and sinker
soaked in oil. periodically .
2. Excessive oiling of the 2. Clean the grooves
needle beds. of the cylinder and
dial of the machine
with petrol.
SURFACE 1. Abrasion due to the 1. Avoid repeated
HARINESS AND contact with rough surfaces. reprocessing of
PILLING 2. Reprocessing of the fabric fabrics.
is also major cause of pilling. 2. Use anti pilling
3. Rough dyeing process and chemical treatments
abrasion machine surfaces. for the fabric .

PRECAUTIONS TAKEN TO MINIMIZE DEFECTS

 Yarn mixing during the feed into the m/c should be prevented.
 Needle and jack should be checked for defects.
 Yarn placement should be correct in the frame.
 Make sure waste fluff had lint does not mix up with the garments.
 Follow bundling and shade sorting procedure continuously.

CONCLUSION
Industrial analysis indicates that the product quality can be improved and cost can be
minimized of the knitting process. Some faults can be easily avoided by respecting
some fundamental pre requites on the machine such as use of positive yarn feeder
and by following the maintenance and cleaning schedule.