QUALITY ISSUES AND

PREVENTIVE METHODS

Report by
BSc. Interns 2023, Department of Textile and Apparel Engineering, University of Moratuwa
FABRIC CUTTER ISSUE

Definition

Fabric cutter is related to the improper function of the cutter in the knitting machines. The cutting
edge of the fabric may look ragged or wavy.

Causes

This is caused by the issue of a malfunctioning fabric cutter in the knitting machine. This is a
mechanical issue, and the malfunctioning blade needs to be repaired.

 Inconsistent and incomplete cutting of the fabric/thread.

 The presence of obstructions, such as thread or fabric pieces, in the blade area, affecting the
cutter's performance.
 Dull or damaged blade, hindering efficient cutting.
 Misalignment of the blade with the cutting mechanism.

Remedies

The already damaged fabric cannot be remedied in this case. The fixing of the cutting blade can
remove the issue for new fabrics.
KNITTING MACHINE CLEANING LINE

Definition

The knitting machine cleaning line defect refers to a visible line that appears in the fabric when the
machine is stopped for cleaning.

Causes

The defect occurs when the machine is stopped for cleaning, resulting in the accumulation of dust
and fibers that become knitted into the fabric. This leads to the formation of a visible line in the
stopped area of the machine.

Remedies

The already damaged fabric cannot be remedied in this case. But Preventive measures can be taken
such as maintaining a clean working environment, regular machine cleaning, and proper
maintenance to minimize the accumulation of dust and fibers during the knitting process.
TAKEDOWN ISSUE

Definition

Takedown tension issues refer to problems arising from the incorrect or malfunctioning tension
applied to the fabric during the takedown process in a knitting machine. These issues can result in
various consequences such as fabric irregularities, breakages, or other defects.

Causes

The following causes can contribute to takedown tension issues in a knitting machine:

 Breakages in the gearbox: Damage or breakages in the gearbox mechanism responsible for
controlling takedown tension can disrupt the proper functioning of the tension system.
 Broken nuts: If the nuts responsible for securing the tension components become broken or
damaged, it can lead to instability and inconsistent tension control.
 Loose tension bar: If the tension bar is not properly secured or becomes loose over time, it
can result in fluctuating or inadequate tension applied to the fabric.

Remedies

Mechanical fixing of the takedown tension can remedy this issue.

 Gearbox inspection and repair

 Nut replacement
 Tension bar adjustment
 Regular maintenance and inspection
TEARING LYCRA

Definition

Lycra tearing, commonly known as a "barre" defect, refers to a specific issue caused by excessive
tension in the Lycra yarn. This defect is characterized by a visible line or streak across the fabric's
surface, resembling a barre.

Causes

Uneven or incorrect tension of lycra yarn during manufacturing

Remedies

Mechanical fixing of the lycra yarn tension can remedy this issue.
CONTAMINATIONS

Definition

Contamination in knitted fabrics refers to the presence of foreign materials or color spots that occur
due to various factors during the knitting process.

Causes

The following causes can contribute to contamination issues in a knitting machine:

 Yarn floats from neighboring machines: Contamination can occur when different types of
yarns are used on neighboring knitting machines. If the yarns are not properly contained
within their respective machines, they can float and unintentionally cross over to
contaminate adjacent fabrics during the knitting process.
 Dust and dirt particles: External factors such as dust and dirt in the knitting environment can
settle on the fabric during the production process. These contaminants can adhere to the
fabric surface, resulting in visible spots or discoloration.

Remedies

Already contaminated fabrics can be remedied by removing the contaminations manually, to

prevent future contamination the below steps can be followed.

 Proper machine separation: To prevent contamination from neighboring machines, it is

essential to implement proper separation measures. This can be achieved by using physical
barriers such as polythene covers or partitions between the machines. This helps to
minimize the chances of yarn floats crossing over and contaminating adjacent fabrics.
 Regular cleaning and maintenance: Maintaining a clean and dust-free knitting environment
is crucial. Regular cleaning of the machines, work areas, and surrounding spaces helps
reduce the presence of dust and dirt particles that can cause contamination. Proper
maintenance of the machines also ensures their optimal performance and minimizes the risk
of contaminants being introduced during the knitting process.
 Quality control checks: Implementing stringent quality control measures throughout the
production process is important to detect and address contamination issues. Regular
inspections and visual checks can help identify any visible spots or color variations in the
fabric. Contaminated areas can be manually removed or addressed during the picking
operation, where contaminants are manually extracted from the fabric.
DIRTY MARKS

Definition

Dirty marks on knitted fabrics refer to visible stains or discolorations that occur due to the presence
of contaminants, including dirt, oils, and other substances, on the fabric surface. These marks can
significantly impact the overall appearance and quality of the fabric.

Causes

The following causes can contribute to dirty marks in knitted fabrics.

 Environmental factors: Contaminants present in the manufacturing environment, such as

dust, dirt, and airborne particles, can settle on the fabric during the production process.
Factors like inadequate cleanliness or poor ventilation contribute to the presence of these
contaminants.
 Handling and storage: Improper handling and storage practices can introduce contaminants
onto the fabric. For example, oils or greases from machinery, human contact with unclean
hands, or contact with dirty surfaces can transfer substances onto the fabric, resulting in
dirty marks.

Remedies

 Chemical treatment: Applying a suitable chemical treatment to the dirty marks can facilitate
their removal. The chemical is sprayed onto the affected areas, allowing it to penetrate and
dissolve the contaminants. Subsequently, the fabric can be rinsed or washed to completely
remove the marks.
 Spot cleaning: In cases where dirty marks are localized, spot cleaning can be employed. This
involves manually treating the affected areas using a stain remover.
 Preventive measures: Implementing preventive measures can help minimize the occurrence
of dirty marks. This includes maintaining a clean manufacturing environment, regularly
cleaning machinery to prevent oil or grease transfer, and ensuring proper hygiene practices
among workers. Additionally, storing the finished knitted fabrics in clean and controlled
environments can prevent further contamination.
HOLES

Definition

Holes in knitted fabrics refer to visible openings on the fabric's surface, resulting from various factors
such as dusty needles cutting the fabric, yarn tension issues, yarn slubs, cylinder imbalance, and
uneven takedown tension. These holes are typically assigned four points in the four-point system,
indicating a severe defect. Once holes are formed, they cannot be removed from the fabric.

Causes

 Dusty needles: Dust or debris accumulated on the knitting machine's needles can act as
sharp particles, cutting through the fabric during the knitting process and causing holes.
 Yarn tension problems: Incorrect tension in the yarn can lead to irregularities in the knitted
fabric, including holes. Insufficient tension may result in loose stitches, while excessive
tension can cause tight or broken stitches that create holes.
 Yarn faults: Slubs are thicker sections of yarn that are unintentionally incorporated into the
fabric. When these slubs are present in the knitting process, they can create weak points
that are prone to forming holes. Also, other yarn faults and low twist can lead to lower yarn
strengths and holes.
 Cylinder imbalance: An imbalanced knitting machine cylinder can cause uneven fabric
tension during the knitting process. This imbalance can lead to irregularities in stitch
formation, potentially resulting in holes.
 Uneven takedown tension: Takedown tension refers to the force applied to the knitted
fabric as it is removed from the knitting machine. If this tension is unevenly distributed, it
can cause stretching or distortion, leading to the formation of holes.
 RPM too high in the machine can also form holes.
 In double jersey machines higher needle heights in the dial, and cam unbalances can also
create holes in the fabric.

Remedies

 Regular needle maintenance: Cleaning and maintaining knitting machine needles is crucial to
prevent dust or debris buildup that can cut the fabric. Regular cleaning and lubrication of the
needles can help reduce the risk of needle-related holes.
 Proper yarn tension control: Monitoring and adjusting yarn tension according to the
specifications of the fabric being knitted is essential. This ensures that the yarn is
appropriately tense, minimizing the occurrence of holes due to lose or tight stitches.
 Yarn quality control: Ensuring the quality of the yarn used is important. Proper selection of
yarn with minimal slubs or irregularities can help prevent the formation of weak points that
can lead to holes.
 Machine calibration and maintenance: Regularly calibrating and maintaining knitting
machines, including checking for cylinder balance, is crucial. This helps ensure that the
machine is operating optimally, minimizing the risk of holes caused by uneven tension or
stitch formation.
NEPS

Definition

Neps in knitted fabrics refer to small, tangled fibers or knots that are visible on the fabric surface.
These neps are a result of pre-existing defects and contaminations that exist within the yarns used in
the knitting process.

Causes

Cotton harvesting factors: Neps can originate from defects and contaminations present in the cotton
fibers used to create the yarns. Dust, dirt, and other impurities from the cotton harvesting process
can become entangled within the fibers, leading to the formation of neps.

Remedies

Dyeing and scouring: Scouring refers to the process of removing impurities and contaminants from
the fabric. During scouring, treatments such as washing or chemical treatments are utilized to
eliminate neps and ensure the fabric's cleanliness and quality. The dyeing stage of fabric production
often includes treatments that help remove neps. Various chemical agents and processes are
employed during dyeing to break down and eliminate the tangled fibers, resulting in the removal of
neps.
NEPS

Definition

Neps in knitted fabrics refer to small, tangled fibers or knots that are visible on the fabric surface.
These neps are a result of pre-existing defects and contaminations that exist within the yarns used in
the knitting process.

Causes

Cotton harvesting factors: Neps can originate from defects and contaminations present in the cotton
fibers used to create the yarns. Dust, dirt, and other impurities from the cotton harvesting process
can become entangled within the fibers, leading to the formation of neps.

Remedies

Dyeing and scouring: Scouring refers to the process of removing impurities and contaminants from
the fabric. During scouring, treatments such as washing or chemical treatments are utilized to
eliminate neps and ensure the fabric's cleanliness and quality. The dyeing stage of fabric production
often includes treatments that help remove neps. Various chemical agents and processes are
employed during dyeing to break down and eliminate the tangled fibers, resulting in the removal of
neps.
THICK PLACES

Definition

Thick places in knitted fabrics refer to sections of the yarn that have increased thickness. These thick
sections are incorporated into the fabric during the knitting process, leading to visible horizontal
thick lines in certain areas of the fabric.

Causes

Yarn irregularities: The presence of thick places in yarn can occur due to irregularities or
inconsistencies in the spinning or manufacturing process. Variations in fiber density or spinning
tension can lead to thicker sections within the yarn.

Remedies

Unfortunately, once the fabric is knitted, it is not possible to remove or eliminate the thick places.
The defect becomes a permanent part of the fabric's structure. However, implementing strict quality
control measures for yarn selection is important to prevent this issue.
THICK YARN

Definition

Thick yarn in knitted fabrics refers to a continuous, thick section that spans the entire width of the
fabric. This thick section repeats periodically along the length, creating a spiral pattern. It is a result
of yarn defects present in the manufacturing process.

Causes

Yarn irregularities: The presence of thick yarn sections can occur due to irregularities or
inconsistencies during the yarn spinning or manufacturing process. Variations in fiber density,
spinning tension, or yarn composition can lead to sections of increased thickness.

Remedies

Similar to thick places, once the fabric is knitted, it is not possible to remove or eliminate the thick
yarn defect. The defect becomes a permanent part of the fabric's structure. Implementing strict
quality control measures for yarn selection is vital to prevent this issue.
THIN PLACE

Definition

Thin yarn in knitted fabrics refers to sections of the yarn that are thinner than the adjacent areas,
resulting in visible lines or stripes in the fabric.

Causes

Yarn irregularities: The presence of thin yarn sections can occur due to irregularities in the spinning
or manufacturing process. Factors such as variations in fiber thickness, inconsistent spinning tension,
or yarn defects can result in sections of reduced thickness.

Remedies

Similar to thick places, once the fabric is knitted, it is not possible to remove or eliminate the thin
yarn defect. The defect becomes a permanent part of the fabric's structure. Implementing strict
quality control measures for yarn selection is vital to prevent this issue.
THIN YARN

Definition

Thin yarn in knitted fabrics is a defect similar to thick yarn, characterized by a continuous section of
the yarn that runs along the whole width of the fabric. This thin section can repeat at intervals along
the length of the fabric, creating a visible pattern.

Causes

Thin yarn in knitted fabrics refers to a continuous section of the yarn that spans the entire width of
the fabric. This thin section repeats periodically along the length, resulting in a distinct pattern or
lines in the fabric. It is a result of yarn irregularities present in the manufacturing process.

Remedies

Similar to thick yarns, once the fabric is knitted, it is not possible to remove or eliminate the thin
yarn defect. The defect becomes a permanent part of the fabric's structure. Implementing strict
quality control measures for yarn selection is vital to prevent this issue.
TWO ENDS RUNNING TOGETHER

Definition

Two ends running together in knitted fabrics is a defect that occurs when two yarns are mistakenly
knitted together, both being fed to the same needle in the knitting machine, which is visible on the
fabric surface.

Causes

 Yarn entanglements: Yarns can become entangled or twisted together during the knitting
process, resulting in two ends running together. This can happen due to improper yarn
handling, tension issues, or mechanical problems in the knitting machine.
 Misfeeding: Mistakes in the yarn feeding process can also lead to two ends running
together. If two yarns are erroneously fed to the same needle, they can be knitted together,
resulting in a visible defect in the fabric.

Remedies

Once the defect of two ends running together occurs, it cannot be remedied or corrected. But the
below steps can be taken to prevent this defect from occurring.

 Yarn handling and tension control

 Operator training and vigilance
 Regular machine maintenance can prevent mechanical issues leading to this defect
YARN SLUBS

Definition

Yarn slub is a defect that occurs within the yarn itself, characterized by localized thick places or areas
of increased thickness. These thick sections, known as slubs, are visible along the length of the yarn
and can affect the appearance of the knitted fabric.

Causes

 Fiber irregularities: Yarn slubs can result from irregularities in the fibers used to create the
yarn. Variations in fiber thickness, length, or composition can lead to localized areas of
increased thickness.
 Spinning process: Inadequate spinning techniques or inconsistencies during the spinning
process can contribute to the formation of slubs. Factors such as improper drafting, tension
variations, or yarn breakages can result in thick spots within the yarn.

Remedies

The below steps can be taken to prevent this defect from occurring.

 Yarn selection
 Quality control checks
RIDDLE MARKS

Definition

Riddle marks in knitted fabrics are wrinkles or creases that occur due to friction or wrinkling during
the handling of the fabric.

Causes

 Improper handling: Riddle marks can result from mishandling the fabric during various
stages of production. Excessive tension, stretching, or abrupt changes can lead to the
formation of riddle marks.
 Wrinkling or creasing: When yarn is subjected to wrinkling or creasing during handling or
storage, riddle marks can occur. This can happen when the fabric is folded, twisted, or
compressed in a way that causes permanent marks or indentations.

Remedies

 Pre-setting process: Most riddle marks can be removed during the pre-setting process, which
involves steaming or heat treatment of the fabric. The application of steam or heat helps
relax the fibers and smoothen out the marks caused by handling. While most riddle marks
can be removed during the pre-setting process, there may be instances where the defect
cannot be fully eradicated.
 Prevention through proper handling: To minimize the occurrence of riddle marks, it is
important to handle the yarn with care and avoid excessive tension or stretching.
UNEVEN DYE

Definition

Uneven dyeing is a defect that occurs during the yarn dyeing process, resulting in variations in color
intensity or shade across the yarn. This defect manifests as visible uneven shades along the yarn
repeat, where some sections appear darker or lighter than others.

Causes

 Dyeing inconsistencies: uneven dyeing can be caused by inconsistencies in the dyeing

process, such as uneven distribution of dye, inadequate dye penetration, or improper dye
fixation. Variations in dye concentration, temperature, or duration can contribute to uneven
coloration of the yarn.
 Yarn quality or structure: Yarns with uneven fiber distribution, inconsistencies in yarn
thickness, or irregularities in yarn structure can also contribute to uneven dyeing. Such
variations can affect how the yarn absorbs and retains the dye, resulting in visible color
variations.

Remedies

Unfortunately, once the defect of uneven dyeing occurs, it cannot be remedied or corrected. The
uneven shades along the yarn repeat become a permanent characteristic of the dyed yarn and
cannot be rectified after dyeing. To prevent this issue the following steps can be taken,

 Quality control in dyeing process: This includes closely monitoring dye concentration,
temperature, and duration to ensure consistent and even dye absorption throughout the
yarn.
 Proper dye bath circulation: Adequate agitation or circulation of the dye bath during the
dyeing process can help promote even distribution of dye and minimize the risk of uneven
dyeing.
 Yarn selection and preparation: Selecting high-quality yarns with uniform characteristics and
consistent dyeing properties can help minimize the occurrence of uneven dyeing.
WAVINESS

Definition

Waviness in knitted fabrics is a defect characterized by a wavy or rippled appearance in the yarn
repeat after knitting with yarn-dyed yarns.

Causes

Uneven takedown tension: The tension applied during the takedown process, where the knitted
fabric is removed from the knitting machine, can impact the appearance of the yarn repeat. Uneven
tension across the fabric width can result in varying degrees of waviness.

Remedies

 Finishing processes: In some cases, waviness can be rectified during the finishing stage.
Finishing processes such as steaming, or heat treatment can help relax the fabric and reduce
the waviness.
 Adjusting takedown tension: Implementing proper tension control during the takedown
process can help prevent or minimize waviness.
 Knitting machine adjustments: Proper machine setup and maintenance are crucial to
minimize waviness. Regularly checking and adjusting the knitting machine's tension
mechanisms, needle settings, and feeding systems can help achieve more consistent tension
during the knitting process.
SHADE VARIATIONS

Definition

Shade variations in yarn-dyed fabrics refer to differences in color shade between the fabric and the
intended sample or standard.

Causes

 Dyeing inconsistencies: Shade variations can arise due to inconsistencies in the dyeing
process, such as uneven dye distribution, inadequate dye penetration, or incorrect dyeing
parameters (e.g., time, temperature, pH). Variations in dye concentration, dye bath
preparation, or dye application can result in differences in color shade across the fabric.
 Recipe issues: Incorrect or imprecise dye recipes can contribute to shade variations.
Deviations from the intended dye formulation, including improper dye ratios or incorrect
measurements, can lead to color discrepancies between the fabric and the sample.
 Yarn or fiber variations: Variations in the quality, composition, or characteristics of the yarn
or fibers used in the fabric can also contribute to shade variations. Inconsistent dye affinity
or differences in fiber properties can result in variations in color shade across the fabric.

Remedies

Unfortunately, once shade variations occur in yarn-dyed fabrics, they cannot be rectified or
corrected. The color discrepancies become a permanent characteristic of the fabric and cannot be
altered after dyeing. By implementing rigorous quality control measures, closely monitoring dyeing
processes, and ensuring accurate dye recipes, the occurrence of shade variations in yarn-dyed
fabrics can be reduced.
MECHANICAL WASTAGE

Definition

Mechanical wastage refers to the defects that occur in fabric as a result of mechanical issues or
errors during machine maintenance or repairs. These defects can encompass a range of physical
imperfections, as well as the presence of dirt or oil residues.

Causes

 Machine malfunctions: When a machine is not functioning properly or has mechanical

issues, it can lead to various defects in the fabric. For example, misaligned needles, worn-out
machine parts, or faulty mechanisms can cause physical damage to the fabric during the
knitting or production process.
 Improper machine maintenance: If the machine is not maintained regularly or correctly, it
can contribute to mechanical wastage. Insufficient lubrication, inadequate cleaning, or
neglecting to replace worn-out components can result in defects in the fabric.
 Dirt and oil contamination: During machine repairs or maintenance, the presence of dirt,
dust, or oil can inadvertently transfer onto the fabric, causing visible stains or marks. These
contaminants can affect the fabric's appearance and quality.

Remedies

By emphasizing skilled mechanics, regular machine inspections, and proper maintenance

procedures, manufacturers can reduce the occurrence of mechanical wastage in fabrics.
Additionally, ensuring a clean working environment can help prevent the transfer of dirt or oil
contaminants to the fabric during machine repairs.
WRONG REPEAT

Definition

Incorrect yarn feeding sequence in yarn-dyed fabric refers to a mistake or error in the order or
arrangement of yarns during the knitting process, leading to issues in the fabric repeat. These issues
become apparent when compared to the approved sample and result in visible discrepancies in the
pattern or design of the fabric.

Causes

 Human error: Inaccurate yarn feeding sequence can occur due to human error or oversight
during the setup or operation of the knitting machine. Mistakes in yarn placement or
incorrect programming of the machine can lead to a mismatch between the intended
pattern and the actual fabric outcome.
 Communication errors: Lack of clear instructions or miscommunication between personnel
involved in the production process, such as designers, technicians, or machine operators,
can result in incorrect yarn feeding sequences.

Remedies

It is important to note that once the fabric is knitted with an incorrect yarn feeding sequence, the
resulting discrepancies in the fabric repeat cannot be repaired or rectified. Therefore, utmost care
and attention should be given to ensuring the accurate and proper arrangement of yarns during the
knitting process to achieve the desired pattern and appearance in the final yarn-dyed fabric.
LATCH CLOSE

Definition

A latch close is a knitting defect that occurs when a latch on the knitting needle fails to open and
catch the yarn, resulting in a missed stitch along a wale in the fabric.

Causes

 Faulty knitting needle: The latch on the knitting needle may be damaged, worn-out, or
improperly aligned, preventing it from opening and capturing the yarn during the knitting
process. This can result from regular wear and tear, inadequate maintenance, or
manufacturing defects in the needle.
 Improper needle setting: Incorrect adjustment or improper setting of the knitting machine
needles can contribute to latch close defects. If the needles are not positioned correctly or if
there is a mechanical issue with the needle bed, the latches may fail to open properly.

Remedies

 Needle maintenance and replacement: Regular maintenance of knitting needles is essential

to ensure their optimal performance.
 Proper needle alignment and adjustment: Ensuring that the knitting machine needles are
correctly aligned and adjusted is crucial to prevent latch close defects.
 Machine calibration and inspection: Regular calibration and inspection of the knitting
machine, including the needle beds and related mechanisms, can help identify any issues or
misalignments that may contribute to latch close defects.

LYCRA VISIBLE NOR FACE SIDE

Definition

Lycra visible on the back side of the fabric, also known as "lycra visible not face side," is a defect that
commonly occurs in 2*2 knitted fabrics. In this defect, the lycra yarn becomes visible on the back
side of the fabric, whereas it should ideally be hidden within the structure.

Causes

 Needle problems: Issues with the knitting machine needles, such as misalignment, improper
hooking or looping, or worn-out needles, can contribute to the lycra yarn becoming visible
on the back side of the fabric. Insufficient or excessive penetration of the lycra yarn by the
needles can result in this defect.
 Machine setting issues: Incorrect machine settings, including tension settings, stitch length,
or cam adjustments, can affect the proper incorporation of the lycra yarn within the fabric
structure. Improper settings may cause the lycra yarn to be exposed on the back side instead
of being hidden.
 Yarn tension and characteristics: Variations in yarn tension, including inadequate tension on
the lycra yarn, can contribute to its visibility on the back side of the fabric. Yarn
characteristics, such as thickness or elasticity, can also influence the extent to which the
lycra yarn is hidden or exposed.

Remedies

 Needle maintenance and replacement

 Machine calibration and adjustments
 Yarn selection and tension control

DYE MARK
Definition

Dye marks defect in an eco-machine refers to the undesired and noticeable marks or spots that
appear on the fabric surface during the dyeing process, resulting in irregular patches, streaks, or
blotches of color that deviate from the desired uniform dyeing.

Causes for dye marks.

Dye marks occur in the fabric when there is a difference in the shade of the fabric through the width.

Improper pre-treatment on the fabric, irregular winding, tangles which occur in dyeing machine and
using incorrect dyeing program can mainly affect to the dye mark.

Remedies:

 Selecting appropriate dyeing conditions and paying more attention to the correct dyeing
program flow can be reduce the dye marks occurred in dye bath.
 Also, we can use a correct chemical mix in dyeing process. Before adding dyes, fabric should wet
and preparate for the dye absorption. For this process, we use a chemical mixer. As well as, we
can use wetting agents for this process.
 Antifoaming agents also can be used for reduce the dyeing defects.
 If the softeners are not dissolved in water, it may occur the softener marks. We can resolve this
defect dissolving uniform softeners and choosing correct softener as per the fabric.
TANGLE

Definition:

Tangle in an fabric dyeing machine refers to the unintended twisting, knotting, or entangling of
fabric during the dyeing process, resulting in difficulties in achieving consistent and uniform dye
absorption and potential fabric damage.

Causes of fabric tangles

 Incorrectly placing or positioning fabric in the machine. This includes overloading the
machine, unevenly distributing the fabric.
 Insufficient space within the machine for fabric movement can lead to fabric entanglement.
This can occur if the machine is filled to its maximum capacity or if the fabric is tightly
packed.
 Uneven water flow within the machine can result in fabric folding over itself, leading to
tangles.
 Mechanical issues like misaligned parts within the machine, such as rollers, can cause fabric
tangles during the dyeing process.
 Certain fabric types, such as lightweight or slippery fabrics, has a high ability to tangling due
to their inherent properties.

Remedies for fabric tangles

 Proper loading the machine.

Avoid overloading the machine and evenly distribute the fabric within the dyeing chamber.
 Sufficient space and water flow.
Leave adequate space in the machine for fabric movement and ensure even water flow
throughout the dyeing process.
 Regular maintenance
Perform regular maintenance and inspections on the dyeing machine to identify and
address any mechanical issues that may contribute to fabric tangles. Repair or replace
malfunctioning parts promptly.

DYE PATCH
Definition:-

Dye patch refers to an irregularity in the dyeing process that results in patches or areas of uneven
color distribution on the fabric.

Causes for dye patch:-

 Dye patch defect occurs in the fabric when there are patches on the fabric surface. Dyeing
machine is not cleaned properly before dyeing and dyestuff was not properly mixed into
the dye solution are the main causes of dye patches in fabric. Also, the tangles of fabrics
occur in dye bath may cause to the dye patch.
 Dye patches produce the dye unevenness on the fabric surface. Incorrect dye cycle and
adding incorrect chemical mixer can also be affect to the dye patches.

Remedies:-

 After making the issue of dye patches, it is very difficult to correct it. So, we should pay
attent to prevent dye patches before it occurs.

ROPE CREASE
Definition

Rope crease is a line or mark made by folding, pressing, or crushing the fabric rope. It is a type of
wrinkle effect that results in subsequent fabric processing, especially in dyeing process.

Reasons for crease marks:-

 Crease marks can be caused by inadequate preparation and relaxation.

Crease marks often occur when the fabric is folded or bent. The creases form due to the
compression and displacement of the fibers within the material.
 Poor quality of fabrics such as tight construction and high twist yarns.
 Poor suitability of the machine such as not moving folds properly.
 Applying pressure to a surface can cause crease marks.
 Higher liquor ratio.

Remedies:

 In pretreatment, washing the fabric to remove any sizing, finishes, or dirt that could
contribute to creasing.
 Reducing the machine load
 Increase the liquor ratio
 Maintain the proper machine parts such as winch and pump speed.

DYE UNLEVEL
Definition:

Dye unlevel defect refers to the uneven absorption and distribution of dye on the fabric surface
during the dyeing process, resulting in variations in color intensity or hue across the dyed material.

Causes of dye unlevel

 Uneven circulation of dye liquor causing uneven dyeing.

 Improper fabric loading
Incorrectly loading the fabric in the machine can result in uneven dye absorption. Overlapping,
folding, or bunching up of fabric can create areas with limited dye penetration.
 Uneven fabric tension
Unequal tension applied to the fabric during the dyeing process can cause uneven dye
absorption.
 Uneven dye concentration: Variations in dye concentration within the dye bath can lead to
uneven dyeing. Inadequate mixing or improper dye dosage can cause localized areas with higher
or lower dye concentration.

Remedies for dye unlevel defect

 Improper fabric handling or insufficient tension control can contribute to this issue.
 Proper fabric loading.
Ensure that the fabric is loaded evenly and without excessive overlapping or folding. Spread the
fabric evenly in the machine to promote uniform dye absorption.
 Optimal dye liquor circulation
Maintain consistent of the dye liquor throughout the dyeing process. Proper circulation systems
within the machine can help achieve better dye distribution.
 Controlled fabric tension
Ensure that the fabric tension is uniform and properly controlled during the dyeing process.
Avoid excessive tension that can affect to the dye penetration.
 Proper dye concentration: Ensure that the dye concentration is evenly distributed throughout
the dye bath.

DYEING HOLE
Definition:

Dyeing hole defect in dyed knitted fabric refers to small holes or voids that appear on the fabric's
surface after the dyeing process. These holes disrupt the continuity of the dyed color and can affect
the overall appearance and quality of the fabric.

Causes of dyeing hole defect:

 Mechanical stress:
Excessive tension, pressure, or friction during the dyeing process can cause localized damage to
the knitted fabric, resulting in holes.
 Chemical reactions
Improper use of chemicals, such as strong alkaline solutions or reactive dyes, can weaken the
fabric's structure and lead to hole formation.
 Fabric construction
The knitting pattern of the fabric can contribute to the formation of holes if the tension is not
evenly distributed during the dyeing process.
 Dyeing machine and equipment issues

Remedies for dyeing hole defect

 Gentle dyeing process

Use gentle dyeing methods and ensure the dye liquor is evenly distributed to minimize the
chances of localized stress or damage to the fabric.
 Proper fabric loading
Load the fabric carefully in the dyeing machine, ensuring it is evenly distributed and supported
to prevent excessive tension or pressure that can lead to holes.
 Controlled chemical usage
Follow the recommended dyeing procedures and chemical dosage guidelines to prevent
excessive chemical reactions that can weaken the fabric.

QUALITY DEFECTS
Lab sample cut

A lab sample cut refers to a small piece of fabric that is cut from a larger fabric for laboratory testing
and analysis. Lab sample cuts are taken to evaluate various characteristics and properties of the
fabric, ensuring that it meets the required quality standards and specifications. Lab sample cuts are
used for conducting different types of tests and assessments to assess the fabric performance,
quality, and compliance with standards. These tests may include physical, chemical, and mechanical
evaluations.

Shade cut

A shade cut is a sample cut taken from a piece of fabric for color matching and evaluation. It involves
removing a small section of the fabric to assess its color accuracy to the desired shade or color
standard. The purpose of a shade cut is to verify whether the fabric matches the desired shade
specified by the customer, design, or production requirements. It allows for color evaluation and
comparison against a reference standard.

GSM cut

A GSM cut is a sample cut taken from fabric for measuring its GSM (Grams per Square Meter). GSM
is a measure of the weight of the fabric and is an important parameter in determining its thickness,
durability, and overall quality. To measure the GSM, a GSM cutter is used to obtain a correct sample
size. The cut fabric sample is then weighed using a scale. The weight is divided by the area of the
sample to calculate the GSM value.

DIRTY MARKS
Definition:

Dirty marks refers to the appearance of undesirable spots or marks on the fabric surface that affect
its overall visual appeal and quality.

Causes:

 Oil or grease stains: These can occur due to contact with oily machinery or inadequate cleaning
of equipment during the production process.
 Water stains: Watermarks can appear if the fabric is not dried properly after washing or if
uneven drying occurs.
 Environmental factors, such as inadequate storage conditions or improper handling, can lead to
dust or dirt accumulation on the fabric's surface.
 Contaminated chemicals: The use of contaminated or improperly formulated finishing chemicals
can produce marks on the fabric.

Remedies:

 Proper handling: Implement strict quality control measures to ensure that the fabric is handled
in a clean environment, free from oil, dirt, or dust particles.
 Regular equipment maintenance: Regularly clean and maintain machinery and equipment to
prevent oil transfer onto the fabric.
 Proper drying techniques: Ensure thorough and uniform drying of the fabric after washing to
avoid watermarks. Use appropriate drying equipment and methods.
 Improved storage conditions: Store the finished fabric in a clean and controlled environment,
protected from dust, dirt, and other contaminants.

PRESSURE MARK
Definition

Pressure mark defect in finishing fabric refers to a visible and undesirable mark that occurs on the
fabric surface due to excessive pressure during the finishing process. It is a common defect that can
affect the appearance and quality of the fabric.

Causes:

 Uneven pressure distribution: Pressure marks can occur when the pressure applied during
finishing is not evenly distributed across the fabric surface. This can be due to variations in the
machine settings or improper alignment of the fabric.
 Improper padding technique can lead to pressure marks. The padding material helps distribute
pressure evenly, and if it is inadequate, the fabric can get distorted.

Remedies:

 Adjust pressure settings: Ensure that the pressure applied during finishing is within the
recommended range for the fabric type. Check the machine settings and make necessary
adjustments to achieve uniform pressure distribution.
 Improve padding technique: Pay attention to the padding process and ensure that an adequate
amount of padding material is used. Properly align the fabric on the padding material to avoid
distortion.
 Test and adjust: Conduct trial runs with different pressure settings and padding techniques to
identify the optimal conditions for the specific fabric. Regularly monitor the fabric during
finishing to detect pressure marks early and make necessary adjustments.

COMPACTOR STOP MARK

Definition:

Compactor stop mark refers to visible marks that appear on the fabric surface after the compacting
process. They are considered defects because they affect the aesthetic appeal and quality of the
finished fabric.

Causes:

 Uneven compactor pressure: Irregular pressure distribution across the fabric width can lead
to stop marks.
 Insufficient tension in the fabric during the compact process can cause the formation of stop
marks.
 Roller temperature variations: Inconsistent heating of the compaction rollers can lead to the
formation of stop marks.

Remedies:

 Adjust the compactor parameters, including pressure, temperature, and speed, to achieve
uniform compacting across the fabric width.
 Proper fabric alignment: Ensure the fabric is aligned correctly during the compaction process
to maintain uniform tension.
 Roller maintenance: Regularly inspect and maintain the compacting rollers to ensure they
are evenly heated and free from any defects that could cause stop marks.

NARROW WIDTH
Definition:

Narrow width refers to a problem where the finished fabric has a width that is smaller than the
required width.

Causes:

 Improper tension control during the finishing process.

 Mechanical issues with the finishing equipment, such as misalignment.
 Inadequate fabric handling, such as improper alignment.

Remedies:

 Ensure proper tension control by adjusting the tension settings on the finishing equipment.
 Regularly inspect and maintain the finishing machinery to address any mechanical issues.
 Implement proper fabric handling techniques, such as ensuring proper alignment and tension
during feeding and guiding of the fabric.

JOINT DEFECT
Definition:

Joint defect is an imperfection in the finished fabric, specifically at the point where two pieces of
fabric are joined together.

Causes:

 Inadequate seam alignment during the sewing or joining process.

 Insufficient seam strength, leading to seam failure.
 Improper thread tension during sewing, resulting in loose or uneven joints.

Remedies:

 Ensure better alignment of fabric pieces before sewing or joining.

 Use appropriate sewing techniques and stitches to achieve strong and durable seams.
 Regularly check and adjust thread tension during the sewing process.

FINISHING OIL MARKS

Definition:

Finishing oil marks on knitted fabrics refer to visible stains or marks that occur during the finishing
process of the fabric production. These marks typically appear as darker or discolored patches on the
fabric surface due to the presence of oils or lubricants used in the finishing process.

Causes of finishing oil marks:

 Insufficient rinsing: If the knitted fabric is not thoroughly rinsed after the application of finishing
oils can remain on the fabric surface, leading to visible marks.
 Uneven application of finishing oils can result in uneven distribution and concentration of oils on
the fabric, causing visible marks.
 Oil contamination: If the finishing oils used contain impurities or contaminants, they can leave
stains or marks on the fabric during the finishing process.

Remedies for finishing oil marks:

 Ensure thorough rinsing of the knitted fabric after the application of finishing oils to remove any
excess or residual oils. Proper rinsing helps to eliminate the chances of oil marks.
 Apply the finishing oils evenly and in controlled quantities to achieve uniform distribution. This
helps prevent concentrated oil patches that may result in visible marks.

SET UP DAMAGE
Definition

'Set up damage' defect in fabric rotary printing refers to the occurrence of visible damage or
irregularities on the printed fabric that arise during the initial setup stages of the printing process.
These damages typically manifest as streaks, smudges, or inconsistent coloration, which can
significantly impact the quality and appearance of the final printed fabric.

Causes

1. Improper cleaning: Inadequate or improper cleaning of the rotary screens before the printing
process can lead to residual ink or contaminants, which can cause streaks or smudges on the fabric.

2. Improper screen alignment: If the rotary screens are not properly aligned during the setup, it can
result in misregistration or overlap issues, leading to irregular patterns or color bleeding.

3. Insufficient ink coverage: Uneven distribution or inadequate coverage of ink on the rotary screens
can cause patchy or faded areas on the printed fabric.

4. Mechanical issues: Malfunctioning or worn-out parts in the printing machinery, such as faulty
squeegees or worn screens, can contribute to irregularities and damage during the printing process.

Remedies

1. Thorough screen cleaning: Ensure proper cleaning of the rotary screens to remove any residual ink
or contaminants before starting the printing process. Use appropriate cleaning solvents and
techniques recommended by the equipment manufacturer.

2. Accurate screen alignment: Pay careful attention to aligning the rotary screens accurately during
setup to achieve precise registration and avoid overlap issues. Regular maintenance and calibration
of the printing equipment can help in achieving proper alignment.

3. Optimal ink coverage: Ensure that the rotary screens are adequately coated with ink for even and
consistent coloration. Adjust ink viscosity, pressure, and tension settings as necessary to achieve the
desired ink coverage on the fabric.

4. Regular maintenance and inspection: Perform routine maintenance of the printing machinery to
detect and address any mechanical issues promptly. Replace worn-out parts, such as squeegees or
screens, to prevent defects caused by mechanical failures.

By following these remedies and implementing good printing practices, the occurrence of 'set up
damage' defect in fabric rotary printing can be minimized, resulting in high-quality and visually
appealing printed fabrics.

MISS PRINTS
Definition

Misprints in fabric rotary printing refer to printing errors or flaws that occur during the rotary
printing method. Rotary printing is a technique commonly used in fabric printing, especially for
large-scale production. It involves using cylindrical screens or cylinders with engraved designs or
patterns to apply ink onto the fabric.

Causes

Misprints can happen due to various reasons during the rotary printing process. Here are some
common examples:

1. Misalignment: If the fabric is not aligned properly with the rotary screen or if the screen itself is
not aligned correctly, it can result in misaligned or distorted prints. This can cause parts of the design
to be cut off or appear shifted.

2. Registration errors: In rotary printing, multiple color screens or cylinders are used to apply
different colors in registration. If the registration marks are not aligned accurately, it can lead to
misregistration, where the colors do not line up correctly. This can result in overlapping or gaps
between colors, affecting the overall quality of the print.

3. Ink inconsistencies: Irregular ink flow, inconsistent ink viscosity, or insufficient ink coverage can
cause variations in color intensity or uneven printing. This can lead to patchy or streaky prints, where
some areas appear darker or lighter than intended.

4. Blurring or smudging: If there is excessive ink on the rotary screen or if the fabric moves or slips
during the printing process, it can result in blurring or smudging of the design. This can cause unclear
or distorted details, affecting the sharpness and clarity of the print.

5. Fabric imperfections: If the fabric being printed has flaws or imperfections such as uneven texture,
loose threads, or creases, it can affect the printing process. The fabric's surface irregularities can
result in uneven ink absorption or cause disruptions in the printing, leading to misprints.

Remedies

To minimize misprints in rotary printing, it is important to ensure proper setup and calibration of the
printing equipment, accurate alignment of screens and fabric, and regular quality checks throughout
the printing process. Adequate training, maintenance of the machinery, and careful handling of the
fabric can also help reduce the occurrence of misprints.

OUT SETTING
Definition

Out setting refers to a defect that occurs during the fabric rotary printing process. It is characterized
by the misalignment or displacement of the printed design or pattern on the fabric, resulting in an
uneven or distorted appearance.

Causes

1. Fabric Tension: Uneven or excessive tension in the fabric during the printing process can lead to
out setting. Unequal tension across the fabric causes the design to shift or stretch during printing.

2. Improper Registration: Poor registration or alignment of the fabric with the printing screens or
cylinders can result in out setting. If the fabric is not accurately positioned, the design will not be
properly printed in the desired location.

3. Inadequate Drying: Inadequate or insufficient drying of the printed fabric can cause out setting.
When the fabric is not adequately dried before subsequent printing or processing steps, the wet ink
can smudge or shift, leading to misaligned patterns.

Remedies

1. Fabric Tension Control: Proper control of fabric tension is essential to avoid out setting. Ensure
consistent and even tension throughout the fabric during the printing process. Use tension control
devices and mechanisms to maintain uniform tension.

2. Registration Improvement: Enhance the registration or alignment of the fabric with the printing
screens or cylinders. Use precise registration systems and methods to ensure accurate positioning of
the fabric. Regularly calibrate and maintain the printing equipment.

3. Adequate Drying: Ensure thorough drying of the printed fabric before proceeding to the next
printing or processing steps. Use appropriate drying techniques such as hot air dryers, infrared
dryers, or steamers to expedite the drying process. Monitor and control drying parameters like
temperature, airflow, and drying time.

4. Quality Control: Implement stringent quality control measures to detect out setting defects during
the printing process. Inspect the printed fabric at various stages to identify and rectify any
misalignment or displacement issues promptly. This can involve visual inspections, sample testing, or
automated systems.

5. Operator Training: Provide comprehensive training to printing operators regarding the causes and
remedies of out setting defects. Educate them on proper fabric handling, tension control techniques,
registration methods, and drying processes. Skilled operators can minimize the occurrence of out
setting through careful execution of printing operations.

By addressing these causes and implementing appropriate remedies, fabric rotary printing processes
can be optimized to minimize or eliminate the out setting defect, resulting in high-quality printed
fabrics with accurate and well-aligned designs

CHOCKUP MARKS
Definition

In fabric rotary printing, "chock-up marks" or "choke marks" are terms used to describe a specific
issue that can occur during the printing process.

Chock-up marks are unwanted lines or bands that appear on the printed fabric, typically parallel to
the direction of fabric movement. These marks are caused by the fabric getting trapped or squeezed
between the rotary screen and the impression roller, resulting in an uneven ink application and
visible lines on the printed fabric.

Causes

Several factors can contribute to the occurrence of chock-up marks:

1. Improper screen tension: Insufficient tension in the rotary screen can cause the fabric to get
trapped between the screen and the impression roller, leading to chock-up marks.

2. Incorrect impression roller pressure: Inadequate pressure between the screen and the impression
roller can result in the fabric not being pressed evenly against the screen, causing chock-up marks.

3. Uneven fabric feed: Irregular or inconsistent fabric feeding can contribute to chock-up marks. If
the fabric is not fed smoothly and evenly through the printing machine, it may get caught or
squeezed between the screen and the impression roller.

4. Screen damage or misalignment: Damaged or misaligned rotary screens can cause uneven contact
with the fabric, resulting in chock-up marks.

Remedies

To prevent or minimize chock-up marks in fabric rotary printing, the following measures can be
taken:

1. Proper screen tensioning: Ensuring that the rotary screens are properly tensioned and maintained
can help reduce the occurrence of chock-up marks.

2. Optimal impression roller pressure: Adjusting the pressure between the screen and the
impression roller to achieve even and consistent contact with the fabric is important to prevent
chock-up marks.

3. Consistent fabric feeding: Ensuring smooth and consistent feeding of the fabric through the
printing machine can help avoid fabric jams and minimize the risk of chock-up marks.

4. Regular maintenance and inspection: Regularly inspecting and maintaining the printing
equipment, including the rotary screens and impression rollers, can help identify and address any
issues that may contribute to chock-up marks.

By implementing these measures and maintaining proper printing parameters, fabric rotary printing
can produce high-quality prints without chock-up marks or other unwanted imperfections.

SCREEN BLOCK
Definition

In fabric rotary printing, a screen block is a key component used in the printing process. It is a
cylindrical or roller-shaped screen that contains the desired design or pattern to be printed onto the
fabric. The screen block is typically made of a fine mesh material, such as polyester or nylon, which
allows the ink to pass through onto the fabric.

Causes

Here's an overview of how the screen block is used in fabric rotary printing:

1. Design preparation: The desired design or pattern is first created or prepared using specialized
software or by hand. The design is then transferred onto the screen block.

2. Screen engraving: The design is engraved or imaged onto the surface of the screen block. This can
be done through various methods, such as using photochemical processes, laser engraving, or digital
imaging techniques.

3. Ink application: The screen block is mounted onto a rotary printing machine, which typically
consists of a rotating cylinder or roller. Ink is applied onto the screen block, typically using a
squeegee or a specialized ink application system.

4. Ink transfer: As the fabric passes through the rotary printing machine, it comes into contact with
the rotating screen block. The ink is transferred through the fine mesh of the screen onto the fabric,
creating the desired pattern or design.

5. Repeat printing: The rotary printing machine is designed to repeat the pattern continuously along
the length of the fabric. This allows for seamless and continuous printing of large quantities of fabric.

Remedies

The screen block in fabric rotary printing acts as a stencil, allowing the ink to pass through only in the
areas where the design has been engraved. This method offers high precision and accuracy, enabling
intricate designs and patterns to be printed onto the fabric consistently.

It's worth noting that fabric rotary printing is just one of several techniques used in fabric printing,
and each method has its own advantages and limitations.

DENT MARK
Definition

In fabric rotary printing, a dent mark refers to a small indentation or mark that can occur on the
fabric surface during the printing process. It is typically caused by the contact between the fabric and
the rotary screen used in rotary printing.

Rotary printing is a common method of fabric printing where a continuous fabric is passed through a
rotating screen cylinder. The screen cylinder contains the desired design or pattern engraved on its
surface, and as the fabric passes through, the ink is forced through the screen onto the fabric,
creating the printed design.

Causes

1. Screen pressure: If the pressure between the fabric and the rotary screen is too high or unevenly
distributed, it can cause the screen to press into the fabric, leaving indentations or marks.

2. Screen imperfections: Any imperfections or irregularities on the surface of the rotary screen, such
as scratches or dents, can transfer onto the fabric during printing, resulting in dent marks.

3. Fabric tension: Improper fabric tension or handling during the printing process can contribute to
the occurrence of dent marks. Excessive tension or stretching of the fabric can make it more
susceptible to indentation.

4. Inadequate padding or cushioning: The padding or cushioning material used between the fabric
and the rotary screen may be insufficient or not appropriately placed, leading to direct contact
between the fabric and the screen, causing dent marks.

Remedies

To minimize dent marks in fabric rotary printing, several measures can be taken:

1. Proper screen setup: Ensuring that the rotary screen is set up correctly, with appropriate tension,
and free from any defects or imperfections.

2. Optimal pressure control: Maintaining consistent and appropriate pressure between the fabric
and the screen to avoid excessive indentation.

3. Adequate padding: Using suitable padding or cushioning materials between the fabric and the
screen to provide a buffer and minimize direct contact.

4. Fabric handling: Handling the fabric carefully during the printing process to avoid unnecessary
stretching or tension.

By implementing these measures and ensuring proper setup and maintenance of the rotary printing
equipment, dent marks can be minimized, resulting in a higher quality printed fabric.

PRINT SMUDGE
Definition

In fabric rotary printing, "print smudge" refers to a common issue where the printed design or ink
gets blurred or smudged during the printing process. It occurs when the wet ink transfers from the
printing cylinder or screen onto the fabric and smears or spreads beyond its intended boundaries.

Causes

There are several factors that can contribute to print smudging in fabric rotary printing:

1. Improper ink viscosity: If the ink viscosity is too low or if the ink is too runny, it can easily spread or
feather on the fabric, causing smudging.

2. Insufficient drying time: If the printed fabric does not have adequate drying time before it comes
into contact with other surfaces or during subsequent processes, the wet ink can smudge.

3. Incorrect fabric tension: Improper tension or loose fabric during the printing process can cause the
fabric to shift or move, leading to misalignment and smudging of the printed design.

4. Inconsistent pressure: Inconsistent pressure during the printing process can result in uneven ink
distribution, leading to smudging in certain areas.

5. Defective equipment or components: Malfunctioning or worn-out parts of the printing machinery,

such as worn cylinders or damaged screens, can cause improper ink transfer and result in smudging.

Remedies

To prevent or minimize print smudging in fabric rotary printing, several measures can be taken:

1. Ensure proper ink viscosity: Adjust the ink viscosity to an appropriate level for the printing method
and fabric type being used.

2. Optimize drying conditions: Allow sufficient drying time for the printed fabric before it encounters
any contact or further processing.

3. Maintain proper fabric tension: Ensure the fabric is properly tensioned and secured during the
printing process to prevent shifting or movement that can cause smudging.

4. Maintain consistent pressure: Calibrate and maintain the printing equipment to ensure consistent
pressure throughout the printing process, promoting even ink distribution.

5. Regular maintenance: Regularly inspect and maintain the printing machinery and components to
identify and address any issues that could contribute to smudging.

By implementing these measures and maintaining strict quality control, print smudging can be
minimized, resulting in cleaner and more precise fabric prints.

WHITE LINE
Definition

In fabric rotary printing, a "white line" refers to an undesired occurrence where a thin, white or
lighter-colored line appears in the printed design. This line typically occurs along the edge of a
printed color or pattern and is caused by an incomplete or uneven transfer of the printing paste or
dye onto the fabric.

Causes

There are several factors that can contribute to the formation of white lines in fabric rotary printing:

1. Insufficient pressure: If the pressure applied by the rotary screen onto the fabric is inadequate, it
can result in incomplete ink transfer, leaving gaps or lighter areas along the printed edge.

2. Screen misalignment: Improper alignment of the rotary screen can cause a misregistration
between the screens and fabric, leading to white lines where the colors or patterns do not align
correctly.

3. Improper screen tension: Uneven or inconsistent screen tension can cause uneven ink
distribution, resulting in white lines.

4. Screen damage: Damaged or worn-out rotary screens can have areas of reduced ink flow,
resulting in white lines in the printed design.

5. Inadequate ink viscosity: If the viscosity of the printing ink is too low or inconsistent, it can affect
the ink flow and result in incomplete coverage, leading to white lines.

6. Fabric characteristics: Certain fabric characteristics, such as surface texture, porosity, or fiber
content, can affect ink absorption and transfer, potentially contributing to the formation of white
lines.

To minimize white lines in fabric rotary printing, it is important to ensure proper screen tension and
alignment, use appropriate printing pressures, maintain and replace screens as needed, and
consistently monitor ink viscosity. Conducting regular quality checks and adjusting printing
parameters as necessary can help achieve more uniform and accurate ink transfer, reducing the
occurrence of white lines in the printed fabric.

COLOR LINE
Definition

In fabric rotary printing, the term "color line" refers to the point where the color transitions or
changes in a printed design occur. It represents the boundary between different colors or shades in a
pattern.

In rotary printing, a continuous fabric is passed through a rotary screen printing machine. The screen
consists of a cylindrical mesh screen that rotates at a high speed. As the fabric moves through the
machine, the design or pattern on the screen is transferred onto the fabric.

The color line in rotary printing indicates where the transition from one color to another takes place
within the design. Each color has its own dedicated section or area on the screen, and the color line
marks the boundary between these sections. The colors are applied one after another as the fabric
passes through the machine, creating a continuous design with smooth transitions between colors.

Proper alignment and registration of the screen are essential to ensure that the color lines match up
correctly, resulting in a seamless and accurate print. Precise control of the color line is crucial for
achieving high-quality prints with sharp and well-defined color transitions.

In summary, the color line in fabric rotary printing represents the boundary between different colors
or shades within a design, indicating where the transitions occur during the printing process.

WHITE SPOTS
Definition

White spots in fabric rotary printing refer to areas on the fabric where the desired color or design is
missing or less intense, resulting in a visible absence of color. These spots appear as white or lighter
areas amidst the printed pattern.

Causes

Several factors can contribute to the occurrence of white spots in fabric rotary printing:

1. Insufficient ink coverage: If the ink application during the printing process is not adequately
distributed or if the printing pressure is uneven, it can result in areas with less ink coverage, leading
to white spots.

2. Improper registration: In rotary printing, accurate registration is crucial to ensure that the design
aligns correctly with the fabric. If there is misalignment or registration errors, it can cause gaps or
white spots in the printed pattern.

3. Fabric absorbency: Different fabrics have varying levels of absorbency. If the fabric being printed
has uneven or inadequate absorbency, it can lead to inconsistent ink absorption, resulting in white
spots.

4. Ink viscosity: Inadequate control of ink viscosity can affect the flow and penetration of ink into the
fabric. If the ink viscosity is too high or too low, it can result in uneven printing and white spots.

5. Printing speed: In rotary printing, the speed at which the fabric moves through the printing
process can impact the ink transfer. If the printing speed is too fast, it may not allow sufficient time
for the ink to transfer uniformly, leading to white spots.

Remedies

To minimize the occurrence of white spots in fabric rotary printing, it is essential to ensure proper
ink distribution, accurate registration, and consistent ink viscosity. Regular maintenance and
calibration of printing equipment are also necessary. Conducting quality control checks throughout
the printing process can help identify and rectify any issues that may result in white spots.

COLOR SPOTS
Definition

In fabric rotary printing, color spots refer to small, localized areas on the fabric where the color
application or ink deposition is irregular or inconsistent. These spots can appear as small dots or
patches of a different color or intensity compared to the rest of the printed design.

Causes

Color spots can occur due to various factors during the rotary printing process, including:

1. Printing defects: Issues with the printing equipment, such as damaged or worn-out printing
screens, uneven ink distribution, or improper alignment, can result in color spots.

2. Ink inconsistencies: Inconsistent ink viscosity, inadequate mixing, or impurities in the ink can lead
to variations in color deposition, causing spots.

3. Fabric irregularities: Uneven fabric surfaces, imperfections, or variations in fabric texture can
affect the contact between the fabric and the printing screens, resulting in uneven ink transfer and
the formation of color spots.

4. Cleaning or maintenance issues: Insufficient cleaning or improper maintenance of the printing

equipment can lead to residual ink or debris that can cause irregularities in color application.

5. Improper curing or drying: Inadequate curing or drying processes can cause the ink to spread or
migrate, resulting in color spots.

Remedies

To minimize color spots in fabric rotary printing, it is important to ensure proper maintenance and
calibration of the printing equipment, use high-quality inks and screens, conduct regular inspections
and cleaning, and implement consistent ink mixing and application processes. Additionally, fabric
preparation, such as proper pre-treatment and tensioning, can help reduce the occurrence of color
spots by providing a more uniform surface for printing. Quality control measures, including visual
inspections and sample testing, can also help identify and address color spot issues before the entire
printing job is completed.

PRINT UNLEVEL
Definition

In fabric rotary printing, "print unlevel" refers to an issue where the printed design or color appears
uneven or irregular across the fabric's surface. It means that the ink is not evenly distributed or
applied consistently during the rotary printing process, resulting in variations in color intensity,
coverage, or pattern alignment.

Causes

Print unlevel can occur due to several reasons:

1. Uneven pressure: In rotary printing, the fabric passes through a series of engraved rollers or
screens that apply the ink onto the fabric. If there are inconsistencies in the pressure applied by
these rollers, it can result in uneven ink deposition and print unlevel.

2. Roller or screen misalignment: Improper alignment or adjustment of the rollers or screens can
cause variations in the contact between the fabric and the printing surface. This misalignment can
lead to uneven ink transfer and result in print unlevel.

3. Ink viscosity or flow issues: Inadequate ink viscosity or problems with ink flow can cause uneven
ink distribution during the printing process. If the ink is too thick or thin, it may not spread evenly on
the fabric, leading to print unlevel.

4. Fabric tension: Uneven tension in the fabric as it passes through the rotary printing machine can
result in variations in ink absorption and distribution. This can cause print unlevel, particularly if
different sections of the fabric have different tensions.

5. Fabric shrinkage or distortion: If the fabric is not properly prepared or if it undergoes shrinkage or
distortion during the printing process, it can affect the alignment and registration of the design. This
can result in print unlevel where the pattern or colors do not line up correctly.

Remedies

To address print unlevel in fabric rotary printing, it is essential to ensure proper machine calibration,
alignment, and maintenance. Monitoring and adjusting ink viscosity, fabric tension, and other
process parameters can also help achieve more even and consistent prints. Additionally, conducting
regular quality checks and implementing appropriate troubleshooting measures can help identify
and resolve any issues contributing to print unlevel.

BACK SIDE LINES

Definition

In fabric rotary printing, the term "back side lines" refers to the lines or marks that appear on the
backside of the printed fabric. These lines are a common occurrence in rotary screen printing, which
is a popular method used to print continuous patterns on fabrics.

During the rotary screen printing process, the fabric is passed through a series of rotating cylindrical
screens that contain the desired pattern. The screens have tiny holes or apertures through which the
ink is forced onto the fabric, creating the print.

Causes

The back side lines are typically caused by a few factors:

1. Screen registration: Inaccurate registration of the screens can result in misaligned patterns,
causing back side lines. If the screens are not properly aligned, the pattern may not line up precisely,
and this misalignment becomes visible on the back side of the fabric.

2. Screen imperfections: Over time, the screens used in rotary printing can develop imperfections,
such as scratches, uneven mesh tension, or damaged apertures. These imperfections can cause
inconsistencies in the ink flow, leading to back side lines.

3. Ink bleed-through: In some cases, the ink used in rotary printing may bleed through the fabric to
some extent. This can occur if the fabric is too thin or porous, or if the ink viscosity is too low. When
the ink seeps through the fabric, it can create faint lines or marks on the back side.

Remedies

Back side lines are generally considered undesirable in fabric printing, as they can affect the overall
appearance and quality of the printed fabric. To minimize back side lines, it is important to ensure
proper screen alignment, use well-maintained screens, and adjust ink viscosity and fabric selection
to prevent ink bleed-through. Regular maintenance and calibration of the printing equipment can
also help reduce the occurrence of back side lines in rotary printing.

PRINT MIGRATION
Definition

In fabric rotary printing, "print migration" refers to the movement or spreading of dyes or pigments
within the fabric after the printing process. It occurs when the printed design on the fabric transfers
or migrates to adjacent areas, resulting in a blurred or distorted appearance.

Causes

Print migration can happen due to several factors:

1. Dye or pigment mobility: During the printing process, the dyes or pigments used to create the
design are applied to the fabric using a binder or a carrier. In some cases, these dyes or pigments can
have a certain level of mobility, especially if they are not adequately fixed or set.

2. Wet processing: After the initial printing, the fabric undergoes various wet processing steps such
as washing, rinsing, and drying. These processes can sometimes cause the dyes or pigments to move
or spread, leading to print migration.

3. Heat or pressure: In some fabric printing methods, heat or pressure is applied to fix the dyes or
pigments onto the fabric. However, if the heat or pressure is not applied uniformly or if it is
excessive, it can cause the dyes or pigments to migrate.

Print migration can result in a loss of design clarity, color bleeding, or smudging. It can be particularly
problematic when printing intricate or detailed designs that require precise color placement.

Remedies

To minimize print migration in rotary fabric printing, various measures can be taken:

1. Proper fixation: Ensuring that the dyes or pigments are adequately fixed or set onto the fabric is
essential. This can involve using appropriate binders, curing methods, or heat-setting techniques.

2. Testing and quality control: Regular testing and quality checks throughout the printing process can
help identify any potential issues related to print migration. This allows for adjustments and
corrections to be made before full-scale production.

3. Selection of suitable dyes or pigments: Choosing dyes or pigments with low migration properties
can help minimize the risk of print migration. Some dyes or pigments are specifically designed for
improved color fastness and reduced migration.

4. Optimal processing conditions: Controlling factors such as temperature, pressure, and processing
time during heat-setting or fixation processes can help minimize print migration.

By implementing these precautions and ensuring proper printing and post-processing techniques,
the occurrence of print migration can be reduced, resulting in a more precise and vibrant fabric
print.

OVERLAPPING
Definition

In fabric rotary printing, overlapping refers to the intentional overlapping of color or design elements
during the printing process. It is a technique used to create complex patterns, gradients, or layered
effects on fabric.

Rotary printing involves the use of a cylindrical screen or roller, known as a rotary screen, which
rotates at high speed while applying ink onto the fabric. The fabric passes under the rotating screen,
and as it moves forward, different colors or designs are applied in succession.

When overlapping is employed in rotary printing, multiple screens with different colors or design
elements are used in a coordinated manner. As the fabric moves through the printing machine, each
screen applies its respective color or design on the fabric, layer by layer.

The intentional overlapping of colors or designs allows for the creation of intricate patterns, shading,
or blending effects. By carefully aligning the screens and controlling the registration, the overlapping
areas create new colors or visual effects where the colors blend or intersect.

Causes

Overlapping can be used to achieve various effects in fabric rotary printing, such as:

1. Color gradients: By overlapping colors with varying intensities or hues, smooth color transitions or
gradients can be created.

2. Depth and texture: Overlapping different design elements or textures can give the fabric a sense
of depth or texture, adding visual interest.

3. Multi-colored patterns: Overlapping different colored screens can result in multi-colored patterns
or motifs, enhancing the complexity and visual appeal of the fabric.

Remedies

The precise execution of overlapping in rotary printing requires careful coordination and alignment
of the screens to ensure accurate registration. Skilled printers and advanced machinery are often
utilized to achieve the desired effects and maintain consistency throughout the printing process.

LOW CLARITY
'LOW CLARITY' defect in fabric rotary printing refers to a specific issue where the printed design or
pattern on the fabric appears unclear or lacking sharpness. This defect affects the overall visual
quality of the printed fabric, making it less appealing and potentially rendering the design less
distinguishable. To understand this defect better, let's break it down into its definition, causes, and
potential remedies:

Definition

'LOW CLARITY' defect in fabric rotary printing refers to a condition where the printed design or
pattern on the fabric lacks sharpness and appears unclear. It results in a diminished level of detail,
making the design less visually striking and reducing its overall impact.

Causes

1. Insufficient color penetration: Inadequate penetration of printing ink into the fabric fibers can
result in low clarity. This can happen due to improper ink viscosity, inadequate pressure, or incorrect
printing speed.

2. Inadequate screen tension: Insufficient tension in the rotary printing screens can lead to imperfect
contact between the screen and the fabric, causing the design to appear less defined.

3. Poor screen alignment: If the rotary screens are not aligned properly during the printing process, it
can result in misregistration of the colors or patterns, leading to low clarity.

4. Inferior-quality screens: Using screens with low mesh count or screens that are worn out or
damaged can contribute to the low clarity defect.

Remedies

1. Adjust ink viscosity: Ensure that the printing ink has the appropriate viscosity for proper
penetration into the fabric. This can be achieved by adding solvents or thickeners to the ink, as
necessary.

2. Optimize printing parameters: Adjust the pressure, printing speed, and fabric tension to achieve
optimal ink penetration and contact between the screen and fabric. Experiment with different
settings to find the ideal combination.

3. Check and maintain screen tension: Regularly monitor and adjust the tension of the rotary screens
to ensure proper contact with the fabric. This can be done using tension meters and adjusting the
screen frames accordingly.

4. Ensure proper screen alignment: Align the rotary screens accurately to prevent misregistration of
colors or patterns. Use registration marks or sensors to aid in aligning the screens correctly.

5. Use high-quality screens: Invest in high-quality screens with appropriate mesh counts. Replace
worn-out or damaged screens promptly to maintain printing clarity.

6. Conduct regular maintenance: Clean the screens and printing equipment regularly to prevent ink
buildup or debris that can impact print quality. Additionally, inspect and maintain the printing
machine to ensure it is functioning optimally.

By addressing these causes and implementing the suggested remedies, the 'LOW CLARITY' defect in
fabric rotary printing can be minimized or eliminated, resulting in prints with sharper and more
visually appealing designs.
GUM LINE

Definition
In fabric rotary printing, a "gum line defect" refers to a specific issue that can occur during the
printing process. It is characterized by the presence of an unwanted line or streak on the fabric,
typically appearing as a darker or thicker line compared to the rest of the printed design. This defect
is often caused by a buildup or accumulation of excess printing paste or gum at the edges of the
printed area.

The rotary printing method involves using cylindrical screens or rollers to apply the printing paste
onto the fabric. As the fabric passes through the rotary printing machine, the screens rotate and
transfer the design onto the fabric. However, several factors can contribute to the formation of gum
line defects:

Causes

1. Improper setup or adjustment: If the screens or rollers are not correctly aligned or adjusted, it can
result in uneven distribution of the printing paste, leading to the formation of gum lines.

2. Insufficient paste control: Inadequate control of the printing paste viscosity, flow, or pressure can
cause excessive paste to accumulate at the edges of the printed area, resulting in gum lines.

3. Inconsistent fabric tension: Uneven tension or movement of the fabric during printing can lead to
variations in paste deposition, resulting in the formation of gum lines.

4. Insufficient drying or curing: Inadequate drying or curing of the printed fabric can cause the
printing paste to remain wet or sticky, leading to smearing or accumulation of paste along the edges
and resulting in gum line defects.

Remedies

To minimize gum line defects in fabric rotary printing, the following steps can be taken:

1. Proper machine setup: Ensure that the screens or rollers are properly aligned, adjusted, and
maintained to ensure even distribution of the printing paste.

2. Optimize paste control: Monitor and control the viscosity, flow, and pressure of the printing paste
to achieve uniform deposition across the fabric.

3. Maintain consistent fabric tension: Properly tension the fabric during printing to ensure consistent
and even paste application.

4. Adequate drying or curing: Ensure that the printed fabric is adequately dried or cured according to
the recommended guidelines, allowing the paste to fully set and preventing smearing or
accumulation along the edges.

Regular quality checks, troubleshooting, and adjustments during the printing process can help
identify and address gum line defects promptly to achieve high-quality fabric prints.

SELVAGE DAMAGES

Definition
Selvage damages refer to defects that occur at the selvage edges of fabric during the rotary printing
method. The selvage is the self-finished edge of the fabric, often characterized by a different texture
or appearance compared to the rest of the fabric.

In rotary printing, a cylindrical screen or roller with a design or pattern engraved on its surface is
used to apply ink to the fabric as it passes through the rotary printing machine. Selvage damages can
occur due to several reasons:

Causes

1. Uneven ink distribution: If the ink distribution on the roller is not uniform, it can result in uneven
pressure or ink application at the selvage edges, leading to defects.

2. Misalignment: Improper alignment of the fabric with the rotary screen or roller can cause the
pattern or design to be misprinted or partially printed on the selvage edges, resulting in defects.

3. Excessive pressure: Excessive pressure applied by the rotary roller onto the fabric at the selvage
edges can cause distortion, stretching, or compression of the fabric, leading to damage.

4. Fabric tension issues: uneven tension or excessive tension on the fabric as it passes through the
rotary printing machine can contribute to selvage damages, such as fabric puckering, wrinkling, or
distortion.

5. Mechanical issues: Malfunctions or defects in the rotary printing machine, such as misaligned
rollers, worn-out parts, or improper calibration, can result in selvage damages during the printing
process.

Remedies

To minimize selvage damages in rotary printing, it is important to ensure proper alignment of the
fabric with the printing equipment, maintain uniform ink distribution on the roller, optimize fabric
tension, and regularly inspect and maintain the printing machine. Additionally, monitoring the
printing process and conducting quality checks can help identify and address any potential issues or
defects at the selvage edges.

PIN HOLE PRINT

Definition
Pinhole print defects in fabric rotary printing refer to small, undesired holes or spots that appear in
the printed design. These holes are typically very tiny and can be scattered throughout the fabric or
concentrated in specific areas.

Pinhole print defects can occur due to various reasons during the rotary printing process, including:

Causes

1. Blockage in the screen: Rotary printing involves the use of cylindrical screens that transfer the ink
onto the fabric. If the screen has blockages, such as dried ink or debris, it can result in incomplete or
irregular ink transfer, leading to pinhole defects.

2. Improper screen tension: If the screen used in rotary printing is not adequately tensioned, it may
result in uneven ink flow and create pinholes in the printed design.

3. Inadequate ink viscosity: The viscosity of the printing ink plays a crucial role in the printing
process. If the ink is too thick or too thin, it can affect the ink flow and lead to the formation of
pinholes.

4. Fabric surface irregularities: If the fabric being printed has surface irregularities, such as loose
yarns, fibers, or inconsistencies in the texture, it can cause incomplete ink coverage and result in
pinhole defects.

5. Insufficient or uneven pressure: Inconsistent pressure during the printing process can cause
inadequate ink transfer, leading to pinholes in the printed design.

Remedies

To minimize pinhole print defects in fabric rotary printing, it is important to take certain measures:

1. Proper screen maintenance: Regular cleaning and maintenance of screens to prevent blockages
and ensure smooth ink flow.

2. Screen tension control: Ensuring that the screens used in rotary printing are properly tensioned to
achieve uniform ink transfer.

3. Ink viscosity control: Maintaining the appropriate viscosity of the printing ink to ensure consistent
ink flow and coverage.

4. Fabric preparation: Properly preparing the fabric by removing any loose fibers, yarns, or
irregularities that may interfere with the ink transfer.

5. Quality control checks: Conducting regular inspections during and after the printing process to
identify and rectify any pinhole defects.

By implementing these measures and maintaining good printing practices, the occurrence of pinhole
print defects in fabric rotary printing can be minimized, resulting in higher print quality and customer
satisfaction.

UNEVEN PENETRATION

Definition
Uneven penetration is a common defect that can occur in fabric rotary printing. In this context,
uneven penetration refers to the uneven absorption or distribution of ink into the fabric during the
printing process. It can result in irregular or inconsistent color intensity across the printed design,
leading to an undesirable appearance.

Causes

Uneven penetration can be caused by several factors, including:

1. Fabric properties: Different types of fabrics have varying levels of absorbency, which can affect
how ink penetrates the fibers. Fabrics with uneven or inconsistent surface textures, thicknesses, or
fiber compositions may exhibit uneven penetration.

2. Ink properties: The viscosity, composition, and formulation of the ink used in rotary printing can
influence its ability to penetrate the fabric evenly. Ink that is too thick or too thin, or has improper
drying characteristics, may result in uneven penetration.

3. Printing parameters: Factors such as printing speed, pressure, and tension applied during the
rotary printing process can impact ink penetration. If these parameters are not properly adjusted or
controlled, it can lead to uneven distribution of ink on the fabric.

4. Screen condition: The condition of the rotary screen used in the printing process can also
contribute to uneven penetration. Damaged or worn-out screens, inconsistent stencil thickness, or
improper tension can affect the flow of ink and result in uneven penetration.

Remedies

To mitigate the issue of uneven penetration in fabric rotary printing, several steps can be taken:

1. Fabric preparation: Proper pre-treatment of the fabric, including washing, drying, and applying
appropriate pre-treatment chemicals, can help improve ink absorption and promote more even
penetration.

2. Ink formulation and viscosity: Using inks specifically designed for rotary printing and ensuring
proper ink viscosity can contribute to better penetration and color consistency.

3. Printing parameters optimization: Adjusting and controlling printing parameters such as speed,
pressure, and tension to achieve optimal ink flow and penetration can help minimize unevenness.

4. Screen maintenance: Regular inspection and maintenance of the rotary screens, including
replacing damaged screens and ensuring proper tension and stencil thickness, can improve ink
distribution and penetration.

By addressing these factors and implementing proper printing techniques, the occurrence of uneven
penetration defects in fabric rotary printing can be reduced, resulting in more consistent and high-
quality prints.

HIGH PENETRATION

Definition
In fabric rotary printing, the term "high penetration defect" refers to a specific issue that can occur
during the printing process. It refers to an undesirable result where the printing ink penetrates the
fabric excessively, resulting in a blurred or smudged appearance of the printed design.

Causes

Here are some possible causes of high penetration defects in fabric rotary printing:

1. Excessive ink application: If too much ink is applied to the fabric or if the ink viscosity is too low, it
can lead to high penetration. This can happen when the printing machine is not properly calibrated
or when the ink supply system is not well-regulated.

2. Improper fabric preparation: Inadequate pre-treatment of the fabric, such as insufficient washing
or inadequate application of pre-treatment chemicals, can affect the ink penetration. If the fabric
surface is not prepared correctly, the ink may penetrate too deeply into the fibers.

3. Incorrect printing parameters: Factors such as printing speed, pressure, and temperature need to
be properly controlled during the rotary printing process. If any of these parameters are set
incorrectly, it can result in high penetration defects.

4. Ink compatibility with fabric: Different types of fabric require specific types of printing ink. If the
ink chosen is not suitable for the fabric type or if the ink and fabric are not compatible, it can lead to
excessive ink penetration.

Remedies

To address high penetration defects in fabric rotary printing, the following steps can be taken:

1. Adjust ink application: Ensure that the proper amount of ink is applied to the fabric. This may
involve adjusting the ink viscosity, modifying the printing machine settings, or using suitable printing
techniques.

2. Optimize fabric preparation: Adequately prepare the fabric by following recommended pre-
treatment processes, including washing, drying, and applying necessary chemicals or coatings to
control ink absorption.

3. Control printing parameters: Pay attention to printing speed, pressure, and temperature to
achieve optimal ink penetration. Fine-tuning these parameters can help prevent excessive
penetration.

4. Test ink-fabric compatibility: Conduct compatibility tests between the chosen ink and fabric to
ensure they are suitable for each other. This can involve performing trial prints and evaluating the
results before proceeding with the full production run.

By addressing these factors and implementing proper control measures, the occurrence of high
penetration defects in fabric rotary printing can be minimized, resulting in improved print quality.

MISS PRINT LINE

Definition
In fabric rotary printing, a "miss print line defect" refers to a specific type of printing flaw that occurs
during the printing process. It refers to a visible line or mark on the fabric where the printing design
or color is misaligned or inconsistent.

Causes

Here's a more detailed explanation of a miss print line defect in fabric rotary printing:

Fabric rotary printing involves the use of cylindrical screens or rollers to apply patterns and colors
onto fabric. The fabric is fed through the printing machine, and the design is transferred onto it as
the roller rotates.

A miss print line defect occurs when there is a misalignment or inconsistency in the pattern or color
application across the fabric. This can be caused by several factors, including:

1. Registration errors: If the fabric is not properly aligned with the printing rollers or if the
registration marks are inaccurately positioned, it can result in misprints or misalignments, leading to
visible lines or marks on the fabric.

2. Roller imperfections: If the printing rollers are damaged, worn out, or unevenly coated with ink, it
can cause irregularities in the pattern or color application, resulting in miss print lines.

3. Ink flow issues: Inconsistent or insufficient ink flow onto the rollers can lead to uneven printing,
causing gaps or variations in the design, which can appear as miss print lines.

4. Fabric tension: Improper tension of the fabric during the printing process can result in uneven
contact between the fabric and the printing rollers, leading to misprints or miss print lines.

Remedies

To address miss print line defects in fabric rotary printing, it is important to ensure proper alignment
and registration of the fabric, maintain and calibrate the printing equipment, check for roller damage
or wear, and ensure consistent ink flow. Regular quality control checks should be performed to
identify and correct any issues that may cause miss print lines.

PRINT DYE LINE

Definition
Print dye lines refer to visible lines or streaks of color variation on fabric printed using the rotary
printing technique. These lines can be noticed in the form of uneven color distribution, resulting in
an inconsistent appearance of the printed design.

Causes

1. Improper fabric preparation: Inadequate pre-treatment of the fabric, such as insufficient washing
or inadequate desizing, can lead to the formation of dye lines during rotary printing.

2. Uneven color application: Unequal distribution of color paste or dye on the rotary screen can
result in uneven printing, causing dye lines to appear on the fabric.

3. Screen misalignment: Misalignment of the rotary screens can cause irregularities in the printed
design, leading to the formation of dye lines.

4. Inconsistent printing pressure: Inappropriate pressure application during rotary printing can cause
uneven transfer of color, resulting in visible lines or streaks on the fabric.

5. Faulty machinery or equipment: Malfunctioning or poorly maintained rotary printing machines,

including issues with the screens, squeegees, or color paste delivery systems, can contribute to the
occurrence of dye lines.

Remedies

1. Proper fabric preparation: Ensure thorough pre-treatment of the fabric, including adequate
washing and desizing, to eliminate any residues or impurities that may cause dye lines.

2. Optimal color paste consistency: Maintain consistent viscosity and composition of the color paste
to ensure even distribution during printing, thereby reducing the chances of dye lines.

3. Screen alignment: Regularly check and adjust the alignment of the rotary screens to ensure
accurate registration and minimize the formation of dye lines.

4. Controlled printing pressure: Maintain appropriate and consistent pressure during rotary printing
to achieve uniform color transfer and prevent the occurrence of dye lines.

5. Regular maintenance and calibration: Regularly inspect and maintain the machinery and
equipment involved in rotary printing to prevent any defects or malfunctions that could contribute
to dye lines. Calibration of the printing equipment should be performed as needed to ensure optimal
performance.

By implementing these remedies, the occurrence of print dye lines in fabric rotary printing can be
minimized, resulting in high-quality and consistent printed designs on the fabric.

BOWING
Definition

Bowing defect in fabric rotary printing refers to a printing irregularity that results in a distorted
pattern or misalignment of the design on the fabric. This defect manifests as a bowing or bending
effect, where the pattern appears stretched or compressed along the length or width of the fabric.

Causes

1. Uneven tension: Unequal tension applied to the fabric during the printing process can lead to
bowing. Variations in tension can occur due to improper fabric feeding, uneven roller pressure, or
inconsistent tension in the printing screens.

2. Fabric shrinkage: If the fabric has not been properly pre-shrunk or stabilized before printing, it can
shrink during the printing process. The differential shrinkage across the fabric width or length causes
bowing.

3. Improper alignment: Misalignment of the printing screens, either horizontally or vertically, can
cause the pattern to shift or distort, resulting in bowing defects.

4. Fabric distortion: Certain types of fabrics, such as knits or loosely woven textiles, are more prone
to distortion during rotary printing. The inherent elasticity or looseness of the fabric can contribute
to bowing.

Remedies

1. Proper tension control: Ensure that the fabric is fed uniformly and under consistent tension
throughout the printing process. Calibrate the roller pressure and tension settings to maintain even
tension across the fabric width and length.

2. Fabric pre-shrinking: Pre-shrink the fabric before printing to minimize the possibility of shrinkage
during the printing process. This can be achieved through washing, steaming, or heat-setting
techniques.

3. Accurate screen alignment: Ensure accurate alignment of the printing screens, both horizontally
and vertically, to prevent misalignment and pattern distortion. Regularly check and adjust the screen
registration to maintain precision.

4. Fabric stabilization: For fabrics prone to distortion, apply a stabilizing agent or use suitable
interlinings to enhance fabric stability. This can minimize the effects of fabric stretch or distortion
during printing.

By addressing these causes and implementing the appropriate remedies, the occurrence of bowing
defects in fabric rotary printing can be significantly reduced, resulting in improved print quality and
overall customer satisfaction.

SKEWNESS

Definition
Skewness defect in fabric rotary printing refers to an undesirable occurrence where the printed
design or pattern appears distorted or skewed on the fabric. This defect is characterized by the
misalignment or misregistration of the printed motifs, resulting in an irregular or uneven
appearance.

Causes

1. Mechanical Issues: Skewness can occur due to mechanical problems in the rotary printing
machine, such as misalignment of the screens or cylinders, uneven pressure distribution, or
improper tensioning of the fabric.

2. Fabric Tension: Inadequate fabric tension during the printing process can lead to skewness.
Uneven tension across the fabric width can cause the fabric to shift or stretch, resulting in
misalignment of the printed design.

3. Fabric Shrinkage: If the fabric used for printing has a tendency to shrink, it can cause skewness.
Shrinkage can occur due to improper pre-treatment or insufficient relaxation of the fabric before
printing.

4. Inconsistent Ink Application: Uneven or inconsistent application of ink on the printing screens or
cylinders can contribute to skewness. If the ink is not evenly distributed, it can result in
misregistration of the printed design.

Remedies

1. Machine Maintenance: Regular maintenance and calibration of the rotary printing machine are
essential to minimize skewness defects. Proper alignment of screens and cylinders, checking and
adjusting pressure settings, and ensuring smooth operation of the machine can help prevent
skewness.

2. Fabric Tension Control: Effective control of fabric tension is crucial to avoid skewness. The fabric
should be properly tensioned and aligned on the printing machine, ensuring even tension across the
entire width. Tensioning devices and proper fabric handling techniques can be employed to achieve
consistent tension.

3. Fabric Relaxation: Prior to printing, the fabric should undergo adequate relaxation to minimize
shrinkage. Pre-treatment processes, such as steaming or washing, can help relax the fabric and
reduce the likelihood of skewness caused by shrinkage.
4. Ink Control: Ensuring consistent and uniform ink application is vital in preventing skewness. Proper
ink formulation, regular viscosity checks, and maintaining appropriate ink levels on the screens or
cylinders can help achieve consistent printing results.

5. Quality Control: Implementing robust quality control measures throughout the printing process is
essential. Regular inspection of printed fabrics, identifying and addressing skewness issues early on,
and making necessary adjustments can help maintain high-quality output.

By following these guidelines and addressing the causes of skewness in fabric rotary printing,
manufacturers can minimize the occurrence of this defect and achieve more accurate and visually
pleasing printed designs.

WAVINESS
Definition

Waviness defect in fabric rotary printing refers to an undesirable pattern distortion or unevenness
that occurs during the printing process, resulting in irregularities in the design. This defect can
detract from the overall appearance and quality of the printed fabric.

Causes

1. Improper tension: Insufficient or uneven tension of the fabric during printing can lead to waviness.
Unequal tension can cause the fabric to stretch or shrink unevenly, resulting in distortions in the
printed pattern.

2. Improper alignment: Misalignment of the fabric during the printing process can cause the design
to shift, resulting in a wavy appearance.

3. Inadequate fabric handling: Poor handling and guiding of the fabric through the rotary printing
machine can lead to wrinkling, puckering, or stretching, resulting in waviness.

4. Inconsistent ink application: Uneven or inadequate application of the printing ink can contribute
to waviness. Incomplete coverage or irregular ink deposition can cause variations in the printed
pattern.

Remedies

1. Proper tension control: Ensure that the fabric is evenly tensioned throughout the printing process.
Use tension devices and adjust them appropriately to maintain consistent tension.

2. Accurate alignment: Ensure precise alignment of the fabric during printing. Use registration marks
or guides to position the fabric accurately on the rotary printing machine.

3. Improved fabric handling: Implement proper fabric handling techniques, including careful guiding
and feeding of the fabric through the machine. Minimize fabric movement and avoid excessive
stretching or wrinkling.

4. Consistent ink application: Ensure uniform and adequate application of the printing ink. Maintain
proper viscosity of the ink and adjust the printing parameters to achieve consistent ink deposition
across the fabric.

By addressing these causes and implementing the suggested remedies, the waviness defect in fabric
rotary printing can be minimized, resulting in improved print quality and a more visually appealing
final product.

REPEA A VARIATION
Definition

Repeating variation defect in fabric rotary printing refers to a defect in which the printed pattern or
design does not align properly or repeats unevenly across the fabric surface. This defect can result in
a distorted or inconsistent appearance of the printed fabric.

Causes

1. Misalignment of the screens or cylinders: If the screens or cylinders used in the rotary printing
process are not aligned correctly, it can lead to repeating variations in the printed design.

2. Uneven tension in the fabric: Unequal tension in the fabric during the printing process can cause
variations in the registration of the design, resulting in repeating defects.

3. Mechanical issues with the printing machine: Malfunctions or mechanical problems in the rotary
printing machine can disrupt the precise registration of the design and contribute to repeating
variations.

4. Improper adjustments of printing parameters: Incorrect settings of printing parameters such as

speed, pressure, or registration can cause repeating defects in the fabric print.

Remedies

1. Proper alignment of screens or cylinders: Ensuring that the screens or cylinders used in rotary
printing are accurately aligned is essential to minimize repeating variations. Regular maintenance
and calibration of the printing equipment can help achieve this.

2. Optimal fabric tension control: Maintaining uniform tension across the fabric during the printing
process can reduce the occurrence of repeating defects. Proper fabric handling techniques and use
of tension control devices are recommended.

3. Regular maintenance of the printing machine: Routine inspections, cleaning, and servicing of the
rotary printing machine can help identify and rectify any mechanical issues that may contribute to
repeating defects.

4. Accurate adjustment of printing parameters: Careful adjustment of printing parameters, such as

speed, pressure, and registration, based on the fabric type and design requirements, can improve
the overall print quality and minimize repeating variations.

It is important to note that addressing and minimizing repeating variation defects in fabric rotary
printing often require the expertise of experienced printing technicians and quality control measures
to ensure consistent and satisfactory results.

DULL SHADE
Definition

Dull shade defect refers to an undesirable outcome in fabric rotary printing where the printed color
appears faded or lacks vibrancy compared to the desired shade. It is characterized by a loss of
brightness and intensity in the printed design, resulting in a dull and less visually appealing
appearance.

Causes

1. Improper formulation or preparation of printing paste: Inadequate or incorrect formulation of the

printing paste, such as incorrect pigment selection, insufficient dye concentration, or improper
binder ratio, can lead to dull shades.

2. Insufficient penetration of printing paste: When the printing paste fails to penetrate the fabric
fibers properly, it hinders the dye's absorption and results in a dull shade.

3. Inadequate curing or fixation: Insufficient curing or fixation of the printed fabric can lead to
inadequate color development, causing the shade to appear dull.

4. Poor color matching: Inaccurate color matching during the design phase can result in dull shades,
as the desired vibrancy and brightness may not be achieved.

5. Incorrect fabric selection: The choice of fabric can influence the appearance of the printed color.
Certain fabrics may not allow the dye or pigment to fully express their vibrancy, resulting in dull
shades.

Remedies

1. Optimization of printing paste formulation: Ensure the correct selection and proportion of dyes,
pigments, and binders in the printing paste to achieve the desired shade and vibrancy.

2. Proper penetration techniques: Employ suitable penetration agents or printing additives to

enhance the absorption and penetration of the printing paste into the fabric fibers, ensuring better
color development.

3. Adequate curing and fixation: Follow appropriate curing and fixation processes, including
temperature, time, and pressure, to ensure proper bonding of the colorants with the fabric fibers
and optimal color development.

4. Precise color matching: Pay close attention to color matching during the design phase, considering
the printing process and the intended fabric to achieve the desired vibrancy and brightness.

5. Selection of appropriate fabric: Choose fabrics that are suitable for rotary printing and allow the
dyes or pigments to exhibit their full vibrancy, thus minimizing the occurrence of dull shades.

It is important to note that the specific causes and remedies for dull shade defects may vary
depending on the printing process, fabric type, and other factors. Therefore, it is crucial to conduct
thorough.

testing, experimentation, and quality control measures to identify and address the root causes of
dull shades in fabric rotary printing.

DOG LEG
Dog leg defect in fabric rotary printing refers to a specific flaw that occurs during the printing
process, resulting in misalignment or distortion of the printed design. It is characterized by an
irregular shift or displacement of the printed pattern along the length of the fabric, resembling the
shape of a dog's hind leg.

Causes

1. Improper Fabric Tension: Uneven or improper tension applied to the fabric while passing through
the rotary printing machine can lead to the dog leg defect. Unequal tension can cause the fabric to
stretch or shrink, resulting in misalignment of the printed design.

2. Mechanical Issues: Malfunctioning or misaligned components in the rotary printing machine, such
as the printing cylinder or fabric transport system, can cause the fabric to move unevenly. This
movement can result in a dog leg defect.

3. Incorrect Registration: Inaccurate registration between the engraved design on the printing
cylinder and the fabric feed can cause the printed pattern to shift or distort. This misregistration may
occur due to errors in the machine setup or inadequate adjustments.

Remedies

1. Fabric Preparation: Ensure that the fabric is properly prepared before printing. This includes
correct washing, drying, and relaxation processes to eliminate any residual tensions or shrinkage. It
is essential to maintain consistent tension across the fabric.

2. Machine Maintenance: Regularly inspect and maintain the rotary printing machine to ensure
smooth functioning. Check for any mechanical issues, misalignment, or worn-out components that
can contribute to the dog leg defect. Timely repairs and adjustments can help prevent this issue.

3. Registration Adjustment: Properly align the engraved design on the printing cylinder with the
fabric feed to achieve accurate registration. Make necessary adjustments to the machine settings,
such as cylinder position and fabric alignment, to minimize misregistration and prevent the dog leg
defect.

4. Operator Skill and Monitoring: Train the machine operators to identify and address the dog leg
defect promptly. They should monitor the printing process continuously, ensuring proper tension,
alignment, and registration. Prompt intervention can help detect and correct any deviations before
they result in significant defects.

By addressing these causes and implementing the suggested remedies, it is possible to minimize or
eliminate the occurrence of the dog leg defect in fabric rotary printing, resulting in higher-quality
printed fabrics.

OTHER PRINTING
Definition

Other printing defects in fabric rotary printing refer to various irregularities or flaws that occur
during the printing process, leading to undesirable patterns, color variations, or distortions on the
fabric. These defects are categorized as "other" since they encompass a range of issues not covered
by specific printing defects.

Causes

a. Improper alignment: Incorrect alignment of the fabric with the rotary screen can result in
misprinted or skewed patterns.

b. Ink inconsistency: Inconsistent ink viscosity, composition, or color mixing can cause variations in
color intensity or improper coverage.

c. Print head issues: Malfunctioning print heads or worn-out components can lead to irregularities in
the printed patterns.

d. Fabric tension: Uneven fabric tension during printing can cause distortions or stretching, resulting
in uneven patterns.

e. Contamination: Presence of foreign particles, dust, or debris on the fabric or within the printing
system can cause print defects.

Remedies

a. Proper alignment: Ensure precise alignment of the fabric with the rotary screen by using
appropriate guides, registration marks, or optical sensors.

b. Ink quality control: Regularly test and maintain consistent ink quality, including viscosity, color
consistency, and proper mixing. Use reliable ink suppliers.

c. Print head maintenance: Regularly inspect and clean print heads, replace worn-out components,
and calibrate the printing system to ensure accurate patterns.

d. Fabric tension control: Use tension control devices or systems to maintain even fabric tension
throughout the printing process.

e. Cleaning and maintenance: Regularly clean the fabric and printing system to remove any
contaminants, dust, or debris that can affect the print quality.

It's important to note that specific remedies may vary based on the equipment, materials, and
processes used in fabric rotary printing. Manufacturers and technicians should consult the
machinery manuals and seek expert advice when addressing other printing defects.

Tight Ends
Definition

Because of tighten of a yarn in a machine, the course made by that yarn shows a kind of a thin line. It
can be seen clearly when the fabric is stretch and inspected under the backlight.

Causes

 IRO clutch is not in the correct position either up or down.

 The feeders rotating belt became loose or the belt was damaged, or the belt is not in the
correct position in the feeder pulley.
 Yarn may not be feed in a positive feeding system.

Remedies

 Check the belt condition and if there is any damage, replace it.
 Adjust the IRO in correct feeding position.
 Check the yarn tightness and if there is any difference, adjust it.

TWO ENDS RUNNING TOGETHER

Definition

It is prominent in the curse direction and shows a thick yarn course in horizontal direction.

Causes

 Two yarn ends (adjacent yarn cones) can be combine together in the creel because of wind.
 Also, when one yarn front end is knotting with the feeding cone back end, they can be
leftover part on the knot place. So, it can feed to the machine and can be show the double
loop line.

Remedies

 Keep correct condition around the knitting machine.

 Cut the additional yarn part after knotting two ends together.

WIDE NEEDLES
Definition

This fault appears prominently in the wale line direction and looks like a wide wale line.

Causes

 When a needle become slightly drawn.

 Also, when the slubs are stuck in the needle grooves.
 And sometimes, after the press off.
 Wrong needle selection.

Remedies

 Have to replace the needle.

 Should be clean the machine.

WRONG YARN
Definition

This defect appears when fed the wrong type or colored yarn to the knitting machine. The fat is
prominent on the course direction.

Causes

 Fed the wrong yarn to creel.

 Knotted the wrong type of yarn to the back end of running yarn cone.

Remedies

 Always feed the correct type of yarn to relevant feeders.

YARN END OUT

Definition

It shows a horizontal line with no loops. Because of that when that fabric is stretched, it will easily
tears. But if that a fabric with elastane yarn, elastane course will be visible but no the main yarn.

Causes

 Yarn is broken due to yarn damage, thick or thin place, abraded with other surfaces or
because of high tension.
 Also, when there is a yarn slubs, it can also affect to miss the catching the yarn on to the
needle and breakage of needle and yarn.
 Also, the yarn is not wound properly in the positive feeder.

Remedies

 Maintain the yarn tension.

 Check the yarn tension and make them all nearly equal with proper amount.
 Clean the machine to remove slubs and other dust particles.
 Maintain proper stop motion system to identify yarn breakage.
 Wrap the yarn in IRO feeder at least 2/3 amount.

CPI HIGH, LOW VARIATION

Definition

This defect can be see when the cpi amount is check in the greige inspection section. visibly not that
much prominent but courses can be see like tighten together.

Causes

 Takedown tension is not applied correctly.

Remedies

 Have to adjust the takedown tension of the machine by checking the two repeats of the
design.
BAD BOWING

Definition

This fault is more prominent in the stripe fabrics. It shows that deviation of stripe lines from
horizontal direction. The stripes will not be perpendicular to the selvage of the fabric.

Causes

 Takedown tension isn’t applied properly.

 Uneven tension across the width of the fabric.

Remedies

 Keep the takedown tension to a proper limit.

 Have to correct the bowing effect in the Mahlo unit in the stenter machine.
 Also in the knitting machine, fabric has to wind to the fabric winding roller in a correct way.
WIDTH VARIATION

Definition

 Shows uneven width of the fabric.

Causes

 The takedown mechanism is not evenly applied because split bars is not evenly pulled.

Remedies

 Correct the takedown tension mechanism.

DOG LEG
Definition

The dog leg effect is a common issue that can occur in striped fabrics. It is characterized by the
appearance of a diagonal distortion or curve in the stripes. It is mostly shows in a stripe fabric which
edges of the stripes getting bend.

Causes

 Main reason to this is the variation of takedown tension.

Remedies

 Can be corrected during the stenter machine processing.

 Cut the fabric along the stripe line and wrap the fabric around the winding roller.

ORANGE FEEL
Definition

The fabric appearance can be seen like orange peel.

Causes

 Can be happen due to the loop length variation. If the speed of the pulley belt changes, the
feeding yarn amount to machine will be change. So, the loop length changes.
 Because of dust in the machine.

Remedies

 Adjust the belt in the correct position of the feeder pulley.

 Clean the machine dust.

PART ROLL
Definition

This fault is a joint point of two fabrics in the same roller.

Causes

 Sometimes because of machine faults or other reasons, 25kg of fabric cannot be knit
continuously. So, two fabrics has to combine with each other to complete the required roll
weight. It causes this fault.

STOP MARK
Definition

This fault will appears on horizontal line directions and show slight color change on the fabric.

Causes

 Because of machine stop suddenly.

 Due to the heat of the machine, this stop mark become more prominent.
 Also, this will prominent due to the stoppage of machine frequently.

Remedies

 Adjust the breaking mechanism of the machine to a level to achieve smooth stop motion.
 Minimize the machine stopping times and stopped time.
 Also , keep cool environment around the machine if it’s possible.

SHARP CENTER CREASE LINE

Definition

This fault appears as a sharp vertical line in the side edges of tubular fabrics.

Causes

Extra tightness of the split rollers.

Nonalignment of the split rollers and bars.

Also, the tightness between the winding bars.

Remedies

Adjust the split roller settings and arrange the distance between winding bars.

FOLDING LINE
Definition

This fault can be seen as a folding line.

Causes

Crease marks come from dyeing.

Edges folding lines.

When curling edges didn’t repaired correctly.

OIL MARK
Definition

This fault will appears as a oil patch on the fabric surface.

Causes

Machine oil leakage.

Breakage of oil supplying and returning pipes.

When slubs goes to the needle grove and oil flow will distort.

Oil seals are broken.

Machines is not cleaned well.

Remedies

Clean the machine during every

Repair the oil leakage points.

Replace the oil supply pipes.

LADDERING
Definition

This fault will mainly appears on interlock fabrics which unravel loops through the wale lines. Also,
this can happen in single jersey fabrics.

Causes

Absence of tooth marks in synthetic fabrics using cotton yarn to avoid laddering.

Also because of a loop breakage in single jersey fabrics.

SOFTENER MARKS
Definition

This occurs in knitted fabrics after applying a softening agent or fabric softener. When a softener is
applied unevenly or more than the required amount, it can leave visible marks or streaks on the
fabric surface, which affects the appearance.

The softener marks normally appear as areas on the fabric that are either darker or lighter in color
compared to the surrounding fabric. They can be seen as streaks, blotches, or patches, depending
on the distribution of the softener during the application process.

Causes

 Improper application: If the fabric softener is not applied evenly across the fabric or if there
is an excessive amount applied in certain areas, it can result in uneven softening and the
formation of marks.
 Absorption issues: Knitted fabrics can have varying levels of absorption due to their
structure and composition. If the fabric does not absorb the softener uniformly, it can lead
to uneven softening and the formation of marks leaving darker or lighter areas on the fabric
surface.
 Chemical compatibility: In some instances, the softener used may not be compatible with
the specific type of fabric, resulting in irregular reactions and the formation of marks.

Remedies

 Dilute softeners properly: Follow the recommended dilution ratios provided by the
manufacturer to ensure consistent application across the fabric.
 Apply evenly: Use appropriate techniques, such as spray application or even distribution
using suitable machinery, to ensure uniform coverage of the softener on the fabric.
However, spray application is expensive. Here, we add the softener chemical to a bath at the
beginning of the Stenter machine and pad the fabric to squeeze out the excessive amount,
ensuring proper absorption.
 Test on a small sample: Before applying the softener to the entire fabric, perform a small-
scale test on a sample to observe any potential issues, such as uneven absorption or color
reactions.

ABRASION MARK:

Definition
This refers to visible damages, marks or rough areas on the surface of the fabric due to friction or
rubbing against another surface.

Causes

 Mechanical stress during production: During the knitting process, if the fabric encounters
excessive tension, pressure, or improper handling, it can lead to localized abrasion marks.
 Excessive rubbing or friction: Continuous rubbing or friction against rough surfaces, such as
machinery parts or other fabrics, can cause abrasion marks.
 Poor fabric quality: In some cases, the use of low-quality yarns or improper yarn selection
for specific applications can contribute to the susceptibility of knitted fabrics to abrasion
marks.

Remedies

 Proper machine settings: Ensure that knitting machines are properly adjusted to minimize
excessive tension or pressure during the knitting process, reducing the risk of fabric
abrasion.
 Lubrication and maintenance: Regularly lubricate machinery parts to reduce friction and
wear. Conduct routine maintenance to keep the knitting equipment in good working
condition and prevent any rough surfaces that could cause abrasion marks.
 Surface treatments or finishes: Apply protective coatings or finishes to the fabric surface,
such as anti-abrasion coatings or treatments, to enhance the fabric's resistance to abrasion
and minimize the formation of marks.

COMPACTOR PLATE MARK:

Definition
Compactor plate mark defect is a common issue that occurs in knitted fabrics during the finishing
process. This defect is characterized by visible crease lines across the fabric's surface, which results
from the pressure exerted on the knitted fabric by the compactor plate. The compactor plate has a
specific pattern - such as diamond, oval, or square - that creates pressure marks or creases that are
difficult to remove.

Causes

 inadequate fabric tension during the compaction process

 insufficient lubrication
 uneven compaction pressure across the fabric width

These factors can weaken the fabric structure and degrade its aesthetic appeal, leading to reject
products.

Remedies

 regulate the fabric tension carefully during the finish

 ensure consistent compaction pressure
 use appropriate lubrication methods
In textile printing, an activator is typically used in conjunction with printing paste to achieve desired
results. The activator, also known as a fixing agent or binder, plays a crucial role in the printing
process by helping the printing paste adhere to the fabric and facilitating the development of color
and design.

When the activator comes into contact with the printing paste, several reactions take place:

Adhesion: The activator helps bind the printing paste to the fabric fibers. It enhances the affinity
between the paste and the textile surface, ensuring good adhesion and preventing the design from
fading or washing out easily.

Crosslinking: The activator promotes crosslinking, which is the chemical bonding between the
molecules of the printing paste. Crosslinking improves the durability and wash fastness of the
printed design. It creates a strong, permanent bond between the colorants and the fabric,
preventing color bleeding or fading during subsequent washes.

Curing: Some activators require heat or other curing methods to fully develop their properties. After
the printing process, the fabric is usually subjected to heat treatment or passed through a curing
chamber. This step activates the activator and facilitates the crosslinking reaction, resulting in a
more vibrant and long-lasting print.

Chemical reaction with colorants: The activator may also interact chemically with the colorants
present in the printing paste. This reaction can affect the shade, hue, or brightness of the colors,
enhancing their appearance and overall colorfastness.

It's important to note that the specific chemical composition and reactions involved can vary
depending on the type of activator and printing paste being used. Different activators are designed
for specific fabric types or printing techniques, and they can have varying effects on the final print
quality. It's crucial to follow the manufacturer's instructions and recommendations when working
with activators and printing pastes to achieve the desired results.