Knit dyeing faults and remedies

Southeast University Department of Textile
Industry : Knit Concern Group | Project : Knit Dyeing Faults and Remedies 1
KNIT DYEING FAULTS AND REMEDIES

Letter of Transmittal
To
Rajib Shaha
Assistant Professor
Department of Textile Engineering
Southeast University
Subject: submission of Project Report on “Knit dyeing faults & remedies”.
Sir,
With due respect & humble, we are the students of Department of Textile
Engineering, Southeast University have been successfully concluded our project. In this stage
we are submitting our Project Report on “Knit dyeing faults & remedies” as a part of our B.Sc.
in Textile Engineering requirement that bears three (03) credit hours under your supervision.
We therefore request and expect that, you will appreciate us with any sort of
recommendations and valued suggestions & will cordially receive this Project Report for your
kind assessment.
Sincerely Yours,
Ariful Islam ID: 2010000400005
Mazadul Hasan ID: 2010000400008
Major : Wet Processing Technology
Batch: 13th
To
Rajib Shaha
Assistant Professor
Sir,
kind assessment.
Sincerely Yours,
Batch: 13th
To
Rajib Shaha
Assistant Professor
Sir,
kind assessment.
Sincerely Yours,
Batch: 13th

Supervising Faculty’s Approval
SOUTHEAST UNIVERSITY
………………………………………………………………
Rajib Shaha
Assistant Professor
I/A 251, 252 Tejgaon, Dhaka
Cell No.: 01726419580
………………………………………………………………
Rajib Shaha
Assistant Professor
Cell No.: 01726419580
………………………………………………………………
Rajib Shaha
Assistant Professor
Cell No.: 01726419580

ACKNOWLEDGEMENT
At first my gratefulness goes to Almighty Allah to give me strength and ability to complete the
industrial training and this report. May your name be exalted, honored and glorified.
Industrial Attachment Course is an academic function of the College of Textile Technology. We are
highly delighted to express our regards & gratitude to honorable Principal Prof. Syed Fakhrul
Hassan.for providing us the chance to complete our Industrial Attachment with Knit Concern Ltd.
Special thanks to our supervising teacher, Rajib Shaha to whom I am extremely indebted for his
tremendous support and guidance throughout my training period, without whose help it would
not have been possible to complete the training successfully.
We also take the opportunity to express our sincerest gratitude to the management,
administration & personnel of Knit Concern Ltd. for their kind assistance. Heartfelt thanks goes to
Engr. A. K. M Mohsin Ahmed, General Manager, Knit Dyeing, Knit Concern Ltd. and Mr. Khalid
Masud, CEO & GM, Yarn dyeing, Knit Concern ltd. for their permission & excellent cooperation
during the period of our training. We would also like to thank Mr. Touhidul Islam Kakon (Dyeing
Manager, Knit) & Mr. Zahid Arman (Dyeing Manager, Yarn) for their sincere support. The generous
support is greatly appreciated. I would also like to thank Production Officers, Senior Production
Officer and other officials of Knit Concern Ltd. for helping me to complete industrial training
successfully. our gratitude also goes to all the employees of Knit Concern Ltd. for their sincere co-
operation, support and valuable advices.
Above all, we would like to acknowledge our deep debt to all teachers of our college & particularly
of Wet Processing Department for their kind inspiration & help, which remain as the backdrop of
all our efforts.
Finally, we would like to acknowledge that we remain responsible for the inadequacies & errors,
which doubtless remain in the following report.
ACKNOWLEDGEMENT
all our efforts.
ACKNOWLEDGEMENT
all our efforts.

Abstract
As a part of the B. Sc. in Textile Engineering, we have completed our Project titled “Knit
Dyeing faults and Remedies ”. We try to focus on the different types of knit Dyeing Faults. We
divided it into the pre treatment faults, Dyeing faults, Finishing Faults. In our literature review We
show the dyeing process Finishing Process and We show the all parameters of dyeing and
finishing like Pressure , Temperature ,time etc . We Discuss all Process and Parameters, done in the
Knit Concern group . We collect all physical sample of fault. We have studied the effect of Knit
Dyeing faults any Find out the Remedies of all faults .
The art of processing of textiles is not new aspect. As the time passes new processes, methods and
machines have been in use to improve the productivity and quality of the processed fabric. In the
era of energy and water saving and eco-friendly processing, to maintain the quality and cost has
become tough task. It is always found that 70% problems of dyeing are attributed to poor
treatment of the fabric. Hence it becomes necessary to give emphasis right from pretreatment to
ultimate dyeing steps to achieve best quality dyed goods. "RIGHT FIRST TIME AND ALL THE TIME
RIGHT" dyeing quality can be easily achieved by strictly adhering to process control parameters of
each and every step of fabric processing. [1]
In this paper an attempt has been made to highlight the various problems encountered due to men,
machine and other factors of processing for damage about the possible causes and remedies of
these dyeing problems helps the processes as a ready recockener for avoiding these problems.
Abstract
Abstract

Project Description:
The study was intended on the topic, ‘Knit dyeing Faults and Remedies’ which carry out a great
importance on the textile sector. Textile and confection sector is one of the leading fields of socio-
economical activity, regarding its technological state, economical efficiency and social interaction.
Marketing conditions became harder within the recent years of 2000, urging this crucial sector for
the economy to aim taking new and radical measures and bounding it to determine the quality.

Origin of the report
Name of the factory: KNIT CONCERN LIMITED
Type : 100 % Export Oriented Composite knitwear Industry
Year of Establishment : 1998
Status ( Legal Structure ) : Private Limited Company
Annual Production capacity : 10000 ton of knit fabric ( Open & tubular form )
Total Manpower: Around 8000
Address : 62 ,Water Works Road, Godnail.Narayanganj, Bangladesh.
Telephone Number : +88 – 02 - 7641086
Fax Number : + 88 – 02 – 7641087
URL : http://www.knitconcern.com
location of KCL: Knit Concern Limited is located at Godnail , in Narayanganj about 18 km from the EPZ.
Knit Dyeing Section:
It has two section of knit dyeing floor – KCL (Old floor) & KCA (New floor). Each contains around 100
thousands square ft area.
Production capacity: approximately 50 ton/day
Fax Number : + 88 – 02 – 7641087
Fax Number : + 88 – 02 – 7641087

CONTENTS
Page No.
Acknowledgement………………………………………………………………........................................3
Abstract……………………………………………………………………………………………………………………..4
Project Description…………………………………………………………………………………………………….5
Origin of the report……………………………………………………………………………………………………6
1. INTRODUCTION…………………………………………………………………………………………………..8
2. PROJECT OBJECTIVE ……………………………………………………………………………………………9
3. LITURATURE REVIEW:
3.1. Dyeing Flow Chart ………………………………………………………........................................11
3.2 SCOURING PROCESS….............................................................................................12
3.3 Special Process: Deminelilazation Hot ...…………………………………………………………….13
3.4 Dyeing : ……………………………………………………………………………………………………………..14
3.5 Finishing ……………………………………………………………………………………………………………..14
3.7 DEFECT …………..…………………………………………………………………………………………………..13-15
3.7.1 Defination Of Fault ……………………………………………………………………………….15-16
3.7.4 Dyeing Faults…………………………………………………………………………………………17
3.7.4 Types of Dyeing Faults ……………………………………………………………………….. 18-19
4 . EXPERIMANTAL DATA
4.6 Yarn …………..………………………………………………………………………………………………………..20
4.7 Grey Fabrics …………..……………………………………………………………………………………………20
4.8 Chemical list …………..……………………………………………………………………………………………21
4.9 Dyes list…………..…………………………………………………………………………………………………..22-23
4.4 Knit Dyeing Operation process : ……………………………………………………………………………24
4.6 Inspection of Grey Fabric from knitting section to Dyeing: ……………………………………24-25
4.5 Production parameters: …………………………………………………………………………………………25
4.7Parameters of dyeing & Finishing M/C: …………………………………………………………………25-29
5. ANALYSIS DATA
5.1 Grey Fabric faults ………………………………………………………………………………………………..31-34
5.2 Pre Treatment faults ……………………………………………………………………………………………35-39
5.3 Optical brightener fault…………………………………………………………………………………………40-42
5.3 Finishing Faults ……………………………………………………………………………………………………..43-49
5.4 Dyeing Faults………………………………………………………………………………………………………….50-63
6.RESULT & DISCUSSION ………………………………………………………………………………………………66-74
CONCLUTION
REFIRANCE
THANKS
CONTENTS
Page No.
Abstract……………………………………………………………………………………………………………………..4
1. INTRODUCTION…………………………………………………………………………………………………..8
3.4 Dyeing : ……………………………………………………………………………………………………………..14
3.5 Finishing ……………………………………………………………………………………………………………..14
3.7 DEFECT …………..…………………………………………………………………………………………………..13-15
3.7.4 Dyeing Faults…………………………………………………………………………………………17
4.6 Yarn …………..………………………………………………………………………………………………………..20
4.7 Grey Fabrics …………..……………………………………………………………………………………………20
4.8 Chemical list …………..……………………………………………………………………………………………21
4.9 Dyes list…………..…………………………………………………………………………………………………..22-23
5. ANALYSIS DATA
5.4 Dyeing Faults………………………………………………………………………………………………………….50-63
CONCLUTION
REFIRANCE
THANKS
CONTENTS
Page No.
Abstract……………………………………………………………………………………………………………………..4
1. INTRODUCTION…………………………………………………………………………………………………..8
3.4 Dyeing : ……………………………………………………………………………………………………………..14
3.5 Finishing ……………………………………………………………………………………………………………..14
3.7 DEFECT …………..…………………………………………………………………………………………………..13-15
3.7.4 Dyeing Faults…………………………………………………………………………………………17
4.6 Yarn …………..………………………………………………………………………………………………………..20
4.7 Grey Fabrics …………..……………………………………………………………………………………………20
4.8 Chemical list …………..……………………………………………………………………………………………21
4.9 Dyes list…………..…………………………………………………………………………………………………..22-23
5. ANALYSIS DATA
5.4 Dyeing Faults………………………………………………………………………………………………………….50-63
CONCLUTION
REFIRANCE
THANKS

Introduction:
The art of processing of textiles today is well known to all processors. In the past the organized
sector dominated the textile scene; whereas today the decentralized process houses are
predominant. There is a shift in emphasis from the requirements related to finished products to
environment related requirements. Requirements related to the finished product fastness &
other properties of dyestuffs & chemicals, processing etc. shift of emphasis environment
related requirements, cost reduction, security, energy & water saving, toxicology, hygiene legal
regulations, and competitiveness.
Reduction in costs and utilities are achieved by the trend to telescope processes. In order to be
competitive processors would have to give equal if not better quality then the existing material at
the same price. Considering the energy and labour costs, the only means of maintaining a
competitive edge is to lay emphasis on 'Quality'. Good quality does not necessarily mean increased
prices, but in fact would mean "Doing it right the first time" thereby reduce the costs.
Thus with this theme in mind of "Doing it right the first time" we would have to first understand
the problems in the process of dyeing. So, this paper mainly discusses "Problems in Dyeing & its
remedies". The ultimate law of accuracy states, "when working towards a solution of a problem, it
always helps if you know the answer provided, of course you know there is problem". Every
manufacturing unit has a number of problems, however problem solving cannot be considered to
be astrology or palmistry, but it needs the fullest knowledge of basic facts.
Introduction:
Introduction:

Project Object:
1. Research.
2. Analysis various Fault in different process of wet processing and find out the remedial
measure.
3. Remedies of these faults.
4. Selection of raw materials.
5. Product testing.
6. Product Quality improvement.
7. Reduce wastage.
8. To improve the appearance of the fabric, that is, make it more attractive or lustrous by
operations like calendaring, optical whitening, etc.
9. To improve the feel of the fabric by softening, stiffening, etc.
10. To cover faults in the original fabric.
11. To improve wearing qualities of cloth by making it shrink resistant, crease resistant or free
from pills and soiling.
12. To make garments hold their shape and enable them to be worn without ironing.
13. To set the texture of certain fabrics and make others dimensionally stable.
14. To produce stronger and more durable fabrics.
15. To maximize the production.
16. To minimize the production cost.
17. To find out the wasting time during a product making and to minimize the wasting time.
18. Find out the problem restricting the production, generating proper solutions and implement
them in a proper way.
Project Object:
1. Research.
measure.
5. Product testing.
7. Reduce wastage.
Project Object:
1. Research.
measure.
5. Product testing.
7. Reduce wastage.

CHAPTER - 3
LITURATURE REVIEW
CHAPTER - 3
LITURATURE REVIEW
CHAPTER - 3
LITURATURE REVIEW

3.1. Dyeing Flow Chart:
Stantoring
Open Compacting
Delivery
Inspection
Dryer
Tube compacting
Inspection
Delivery
Calendaring
Slitting
Fastness Improvement
TtyuuTTreatment
Tube Finish
Gray Fabric Inspection
Diminalilazation
Enzyme Wash
Open Finish
Dyeing
Finishing
Senging
Softening
Sqizer / Padder
Scouring Bleaching
Special Finish
1) Sueding
2) Brushing
3) Creeping
Note: Red Marked area have chance to make fabric Fault
Stantoring
Open Compacting
Delivery
Inspection
Dryer
Tube compacting
Inspection
Delivery
Calendaring
Slitting
TtyuuTTreatment
Tube Finish
Diminalilazation
Enzyme Wash
Open Finish
Dyeing
Finishing
Senging
Softening
Sqizer / Padder
Scouring Bleaching
Special Finish
1) Sueding
2) Brushing
3) Creeping
Stantoring
Open Compacting
Delivery
Inspection
Dryer
Tube compacting
Inspection
Delivery
Calendaring
Slitting
TtyuuTTreatment
Tube Finish
Diminalilazation
Enzyme Wash
Open Finish
Dyeing
Finishing
Senging
Softening
Sqizer / Padder
Scouring Bleaching
Special Finish
1) Sueding
2) Brushing
3) Creeping

3.2 SCOURING PROCESS:
The tern scouring applies to the removal of impurities such as oil, wax gum, soluble impurities and
solid dirt commonly found in textile material. The process consists essentially of treatment with
alkali, a good supply of water is essential.
Bleaching.
Bleaching is destruction of natural coloring matter to produce white fabrics and must be
accomplished with a minimum damage to the cotton being bleached. Bleaching is not a cleaning
process in the sense of scouring. This process does not remove dirt.
Recipe for scouring/ Bleaching : -[9]
Sequestering Agent (Celion BDW) :0.6 gm/L
Wetting Agent ( KappaWet BOSS): 0.7 gm/L
Antifoam (AF 2000) : 0.2 gm/L
Ant crease (Kappavon FCB): 0.8 gm/l
Stabilizer ( Equasec STA ) : 0.1 gm/L
Caustic soda (NaOH): 1 gm/L (scouring Chemical)
H2O2 0.6 gm/L (Bleaching Chemical )
M: L: 1:6 or 1:8
Temperature(▫C): 98 c
Time: 60'
PH
= 11.5-12
3.3 Special Process: Deminelilazation Hot
For Lycra Fabrics : To Remove The lubrication so that it don’t effect on White or light s hade and
don’t create Yellowness on the Fabrics
Recipe :
Basic Chemical (Kappa R 98) : 0.5 gm/l
Parameter: 800
c /20 min
For Slub Fabrics : To Remove the Ferrous (Ca,Mg ,Fe) Salt fron the Thin portion of the Slub yarn So
that it don’t broke during the SCOURING PROCESS react With NaOH and make Hole On the Fabrics
Acid (Oxalic Acid –Core neutralizer ) : 0.5 gm/l
Sequestering Agent (Celion BDW) : 0.3 gm/L
Parameter: 600
c /20 min
Bleaching.
M: L: 1:6 or 1:8
Time: 60'
PH
= 11.5-12
Recipe :
Parameter: 800
c /20 min
Parameter: 600
c /20 min
Bleaching.
M: L: 1:6 or 1:8
Time: 60'
PH
= 11.5-12
Recipe :
Parameter: 800
c /20 min
Parameter: 600
c /20 min

3.4 Dyeing :
The dyeing aim is to colour the textile material in a uniform way. These two stages of the
process are performed more often on Woven fabric or knit, however those can be also
performed on fibre, thread or on some clothing.
Types of dyeing e work for
1. Knit Dyeing
2. Yarn Dyeing
3.5 Finishing:
Textile finishing, in a restricted sense, is the term used for a series of processes to which all
bleached, dyed, printed & certain greige fabrics are subjected before they are put to market.
It’s one of the most important operation in knit processing.
DEFINITION OF DEFECT:
The length of the defect is used to determine the penalty points. Only major defects are
considered. A major defect is any defect, if found on a finished product, would classify the product
as a B- grade. Any defect of a continuous nature shall be assigned four points for each meter in
which it occurs. Severe defects are assigned the maximum four points for each meter in which
they occur.
Example: Regardless of size, a hole would be penalized four points.
Continuing conditions such as barre, side center side shading, roll to roll shading, narrow or
irregular width, creasing, uneven finish shall be counted four points for every meter within the
shipment that is found to contain these conditions, provided that the article that is to be made
from this fabric is classified B-grade due to this fault. The maximum penalty for any one-meter
shall not be more than four points. A minor defect is any defect that does not classify the product
as B-grade because of either severity or location. When inspecting fabric before cutting, it is
necessary to rate questionable defects as major, since the inspector will not know where the
defect may occur on the item.
RUNNING DEFECTS:
Any major defect found to repeat and / or run in a continuous manner will constitute a running
defect. All major running defects must be assigned four penalty points to every meter in the roll
where it occurs.
3.4 Dyeing :
1. Knit Dyeing
2. Yarn Dyeing
3.5 Finishing:
they occur.
RUNNING DEFECTS:
where it occurs.
3.4 Dyeing :
1. Knit Dyeing
2. Yarn Dyeing
3.5 Finishing:
they occur.
RUNNING DEFECTS:
where it occurs.

FULL WIDTH DEFECTS:
A full width major defect would cause that meter of fabric to be assigned four penalty points.
FABRIC WIDTH:
Fabric width will be checked minimum of three times during the inspection of a roll (beginning,
middle and end of the roll).Rolls having width less than the specified are potential problems. In
such cases width deviation of more than 1% would constitute a major fault. Overall, fabric width is
measured from out side of the selvage to the outside of the opposite selvage.
ROLL LENGTH:
Rolls having meters less than that stated on the packing are a problem. Any roll having more than
1% lesser fabric than that specified is rejected. The entire shipment shall be rejected if the total
measured meters in the sample audit are more than 1% short that what is declared on the
packing.
SPLICES:
Rolls can be composed of several spliced parts. No roll shall be accepted that contains a splice less
than twenty five ( 25 ) meters in length unless otherwise expressly accepted. Ensure that the 95%
of the shipment contains 100 meter plus fabric length if the fabric is being used for made - ups. In
case of piece goods, the fabric length and the number of splices / roll are strictly followed as per
the requirement of the customer.
BOW & SKEW:
No roll shall be accepted as first quality that exhibit bow or skew more than:
Fabric Width Maximum Bow or Skew Design Print/dyes Deviation
Up to 45 inches 2.0% 2.0%
60 inches 2.0% 2.0%
90 inches and above 2.0% 2.0%
The above is subject to change if buyer requires a tighter tolerance / nature of design / end use of
the fabric. Tolerance for bowed condition not affecting the full width will be fractionalized
part of the maximums as stated above according to the area affected by the bow. Penalty points
will not be assigned for fabrics found to have conditions of bowing in excess of the above stated
tolerances but shall be noted in the inspection report. And if any fabric exhibits bow or skew
where its end use becomes doubtful, then that fabric will be rejected.
FABRIC ODORS: No roll shall be accepted that exhibits objectionable odors.
FULL WIDTH DEFECTS:
FABRIC WIDTH:
ROLL LENGTH:
packing.
SPLICES:
BOW & SKEW:
60 inches 2.0% 2.0%
FULL WIDTH DEFECTS:
FABRIC WIDTH:
ROLL LENGTH:
packing.
SPLICES:
BOW & SKEW:
60 inches 2.0% 2.0%

HOLES: All defects that break the fabric, regardless of size, shall be penalized a maximum of four
points. A hole consists of two or more broken yarns.
DYEING FAULTS:
The faults which are visible after dyeing are called Dyeing faults . These faults descries the
quality of the fabrics . So to overcome from this faults we have to know the causes and
the remedies of these dyeing faults .
TYPES OF FAULTS
Dyeing faults can be described on the following basic things
1. Unlevelness ( due to dyeing conditions )
i. Ending problems
ii. Cloudy dyeing
iii. Pale areas
2. Unlevelness ( due to material )
i. Barriness
3. Unlevelness ( due to other reasons )
i. Skitterness
ii. Listing
iii. Pale areas after dyeing
4. Reproducibility
i. Deviation of shade
ii. Dyeing too pale
iii. Precipitates in the dyebath
iv. Change of shade
5. Fastness properties
i. Unexpectedly poor light fastness
ii. Unexpectedly poor wet and rub fastness
6. Spots, marks
i. Precipitates in the dyebath
ii. Singeing droplets
iii. Change of shade (e.g. blue spots in brilliant red shades)
iv. Dark spots
v. Specks
vi. Dirt spots
7. Appearance of the goods
DYEING FAULTS:
TYPES OF FAULTS
i. Ending problems
ii. Cloudy dyeing
iii. Pale areas
i. Barriness
i. Skitterness
ii. Listing
4. Reproducibility
ii. Dyeing too pale
iv. Change of shade
6. Spots, marks
iv. Dark spots
v. Specks
vi. Dirt spots
DYEING FAULTS:
TYPES OF FAULTS
i. Ending problems
ii. Cloudy dyeing
iii. Pale areas
i. Barriness
i. Skitterness
ii. Listing
4. Reproducibility
ii. Dyeing too pale
iv. Change of shade
6. Spots, marks
iv. Dark spots
v. Specks
vi. Dirt spots

i. Dimensional stability (shrinkage)
ii. Creasing
iii. Chafe marks
iv. Stitch distortion (knits)
v. Moire effects (on beam)
vi. Lustre
vii. Handle
viii. Pilling (staple fibres)
8. Other problems
i. Difficulty with heavy shades on fine denier yarn
ii. Soiling of machine
iii. Frosting on goods
iv. Poor running of material in subsequent processing
Some definition Wet processing fault:
Crease mark: Uneven heat control during process.
Unevenness: If dyestuffs are not fixed with fabric uniformly causes this problem.
Patches: This problem causes due to different color on some portion of fabric.
Crumple mark: This problem is as like crease mark but looks meeting effect over PC fabric.
Dye stain: Marks of color on fabric surface cause this problem.
Dirty mark: This mark can appear anywhere in fabric.
Rub mark: Caused by friction with metallic component of m/c:
Water sports: One to accumulation of water.
Back Fabric Seam Impression : Backing fabric is often used to cushion fabric being printed.
If there is a joining seam in the backing fabric, an impression will result on printed fabric.
Broken Color Pattern: Usually caused by colored yarn out of place on frame.
Color Out: Color out is the result of color running low in reservoir on printing machine
Color Smears: Color Smears are the result of color being smeared during printing.
ii. Creasing
iii. Chafe marks
vi. Lustre
vii. Handle
8. Other problems
ii. Creasing
iii. Chafe marks
vi. Lustre
vii. Handle
8. Other problems

Crease Mark : Differs from crease streak in that streak will probably appear for an entire
roll. Crease mark appears when creases are caused by fabric folds in the finishing process.
Often discoloration is a problem.
Drop Stitching : Drop stitching is resulted from malfunctioning needle or jack appearing as
holes or missing stitches.
Dye Streak in Printing : Drop stitching is resulted from malfunctioning needle or jack
appearing as holes or missing stitches.
Dye Streak in Printing : Results from a damaged doctor blade or a blade not cleaned
properly. Usually a long streak until the operator notices the problem.
Mottled : Mottles occurs when colors applied unevenly during printing.
Needle Line : Needle Line is caused by bent needle forming distorted stitches in a vertical
line.
Pin Holes : Pin holes along selvage caused by pins holding fabric while it processes
through tender frame.
Printing Machine Stop Mark : Dye or ink smudged along width of fabric as a result of the
printing machine stopping.
Print Out of Repair : Caused by print rollers not being synchronized properly. This results
in various colors of the design not being printed in the proper position.
Puckered Selvage : Usually caused by selvage being stretched in finishing or by uneven
wetting out in sanforization process.
Scrimp: Scrip is the result of fabric being folded or creased when passing through tender
frames.
Water Spots : Water spots are usually caused by wet fabric being allowed to remain too
long before drying, Color migrates leaving blotchy spots.
Pilling : Pilling refers to the forming of little matted balls on the surface of knitted fabrics.
Pilling occurs when soft yarn rubs against itself, resulting in tangled fibers and produces an
uneven and worn look.
line.
frames.
line.
frames.

CHAPTER – 4
Experimental Data
CHAPTER – 4
Experimental Data
CHAPTER – 4
Experimental Data

Raw Materials
KNIT CONCERN GROUP
Type Of Yarn used in knit Concern:
Generally used yarn and their count:
Cotton 24S
, 26S
, 28S
, 30S
, 32S
, 34S
, 40S
Polyester 75D, 100D
Spandex yarn 20D,40D, 70D
Grey Mélange (C-85% V-15%) 24S
, 26S
Ecru Mélange (C-85% V-1%) 24S
, 26S
, 28S
PC (65%Polyester & 35% cotton) 24S
, 26S
, 28S
, 30S
CVC 24S
, 26S
, 28S
, 30S
Grey Fabrics:
Following types of gray fabrics are dyed:
1. Single jersey (All Over print)
2. Single jersey (with Lycra & without Lycra)
3. Polo pique
4. Single lacoste
5. Fleece
6. Interlock (with Lycra & without Lycra)
7. Rib (with Lycra & without Lycra)
8. Different types of collar & cuff Twill tape
9. Terry / Fleece
10. Pointal Rib
CHEMICAL LIST
Name Of Chemical No Name of Item Usage % Name of Company
Antifoam 1 Kappasol AF-2000 0.2 g/l Kapp Chemie GMBH
2 AlbafloW FFC 0.2 g/l Huntsman Singapore
Anti Crease 3 Kappavon FCB 0.8 g/l Kapp Chemie GMBH
4 Argalube NF 0.8 g/l sHanghai xietong (Argus)
Ditergent/ Wetting
Agent
5 Kapp Wet BOS 0.7 g/l Kapp Chemie GMBH
6 Argarep LFD 0.7 g/l Shanghai Xietong (Argus)
7 Fabrevol KNN Conc 0.7 g/l Denimist
Oil Remover 8 Mescour OSRN 0.35 g/l Matex International
9 Gresaw Turbo 0.35 g/l
10 Lanaryl RK 0.35 g/l Benevolent Textile service
Raw Materials
KNIT CONCERN GROUP
Cotton 24S
, 26S
, 28S
, 30S
, 32S
, 34S
, 40S
Polyester 75D, 100D
, 26S
, 26S
, 28S
, 26S
, 28S
, 30S
CVC 24S
, 26S
, 28S
, 30S
Grey Fabrics:
3. Polo pique
4. Single lacoste
5. Fleece
9. Terry / Fleece
10. Pointal Rib
CHEMICAL LIST
Ditergent/ Wetting
Agent
Raw Materials
KNIT CONCERN GROUP
Cotton 24S
, 26S
, 28S
, 30S
, 32S
, 34S
, 40S
Polyester 75D, 100D
, 26S
, 26S
, 28S
, 26S
, 28S
, 30S
CVC 24S
, 26S
, 28S
, 30S
Grey Fabrics:
3. Polo pique
4. Single lacoste
5. Fleece
9. Terry / Fleece
10. Pointal Rib
CHEMICAL LIST
Ditergent/ Wetting
Agent

Sequestering Agent 11 Argaquist ARSK 0.6 g/l sHanghai xietong (Argus)
12 Starquist SD-97 0.6 g/l Startech Chemical
13 Chelion BD W 0.6 g/l Veskim Kimyeve
Stabilizer 14 Argarep CBS 0.1 g/l sHanghai xietong (Argus)
15 StarStab Ex-3 0.1 g/l Startech Chemical
16 Equa Sec STA 0.1 g/l Veskim Kimyeve
Enzyme 17 Unizyme 1000L 0.40 g/l Shanghai Youtell
18 MegaPK (CR9) 0.40 g/l Peli-Bio Chem Technology
Per Oxide Killer 19 Oxilost P 0.3 g/l Veskim Kimyeve
Leveling 20 Albatex –DBC 0.8 g/l Huntsman Singapore
Soaping Agent 21 Kappkom E-12 0.5 g/l Kapp Chemie GMBH
22 Argacel S W 0.5 g/l Shanghai xietong (Argus)
23 Exhaclean BLC 0.5 g/l Denimist
Fixing Agent 24 Albafix ECO Huntsman Singapore
25 Albafix FRD Huntsman Singapore
Cationic Softener 26 MeSoft CCS Flacks Matex International
27 Softner AWs –P Taiwan surfactant
Non ionic Softener 28 Softner E31 0.5 g/l Taiwan surfactant
silicon Softener 29 KappaSoft-SM Kapp Chemie GMBH
30 wiSifact MCH VeSkim Kimyeve
31 wiSifact MIC H VeSkim Kimyeve
Core Neutralizer 32 Invatex 0.5 g/l Huntsman Singapore
Fixing Remover 33 Invalon DAM Huntsman Singapore
Special Chemical 34 Alpclean (Viscose ) VeSkim Kimyeve
36 Invatex CRA (Black) Huntsman Singapore
37 Albatex CO (Special
Levelling)
Huntsman Singapore
38 Rokgent T (M/C waSh )
39 DEfaten FX (Hit SeT) Denge Kimya TeStile
Basic Chemical 40 Gluber Salt 10-80 g/l Treadasia International
41 Caustic Soda 1.5-2 g/l Gojrat
42 SOda ASh 5-17 g/l Hunan Chembrid Indust
43 Oxalic Acid 1 g/l Mollah Enterprise
44 Formic Acid 1 g/l BASF
45 KappaTex R98 (Hydroze) 2-4 g/l Kapp Chemie GMBH
46 Acetic Acid OCI Corporation
Disperse Chemical 47 Albatex AB 45 (Buffer) 2.3g/l Huntsman Singapore
48 Albatex-AR Huntsman Singapore
49 Eripon OS 1 g/l Huntsman Singapore
50 Ultrafil HSD Huntsman Singapore
51 Univadine DIF 1 g/l Huntsman Singapore
52 Univadine DP 1 g/l Huntsman Singapore
Levelling)
Huntsman Singapore
Levelling)
Huntsman Singapore

List Of Dyestuff Used for dyeing at knit concern:
Type Of Dye Number Name Of Dyestuff Name Of Company
Disperse 1 Teracil Red WW-CBS Huntsman
2 Teracil Red WW-3BS Huntsman
3 Teracil Black WNS Huntsman
4 Teracil Red WWFS Huntsman
5 Teracil HF2F WBLS Huntsman
6 Teracil Navy W-RS Huntsman
7 Teracil Navy GRLC Huntsman
8 Teracil Red W4BS Huntsman
9 Teracil Yellow W6BS Huntsman
Reactive 10 Synozol Navy Blue HB Kyug-In synthetic Corporation
11 Synozol Deep Red HB Kyug -In synthetic Corporation
12 Synozol Yellow HB Kyug-In synthetic Corporation
13 Synozol Blue K-BR Kyug-In synthetic Corporation
14 Synozol Turq Blue HF-G 266% Kyug-In synthetic Corporation
15 Synozol Brill Blue RSCL 150% Kyug-In synthetic Corporation
16 Amron Navy HR 2D Amtex Dyechem
17 Amron Yellow HR 2D Amtex Dyechem
18 Amron Yellow HF2GL Amtex Dyechem
19 Amron Brill Red HF2R Amtex Dyechem
20 Amron Red HF2F Amtex Dyechem
21 Amron Red HF4BL Amtex Dyechem
22 Amron Blue HR 2D Amtex Dyechem
23 Amtex Yellow 3R- XF Amtex Dyechem
24 Amtex Red 3B- XF Amtex Dyechem
25 Amron Ultra Red HR2D Amtex Dyechem
26 Drimarine Violet K-2RL Clarient
27 Drimarine Yellow K-2R Clarient
OBA 28 HQ4BK Clarient
Reactive 29 Remazol Blue -RR DyeStar
30 Remazol Yellow -RR DyeStar
31 Remazol Navy-RR DyeStar
32 Remazol Ultra Red RGB DyeStar
33 Remazol Ultra Yellow RGB DyeStar
34 Reactive Starfix Black –B 150% DyeStar
35 Reactive Starfix Yellow 3RFN Hangzhu jihua Import& Export
36 Reactive Starfix Red ED Hangzhu jihua Import& Export
37 Reactive Starfix Yellow Hangzhu jihua Import& Export
38 Reactive Starfix 3RFN Hangzhu jihua Import& Export
39 Reactive Starfix Black ED-HG Hangzhu jihua Import& Export
40 Reactive Starfix Brill Blue KNR Hangzhu jihua Import& Export

Inspection of Grey Fabric from knitting section to Dyeing:
 Checking flow-chart –
Knitted fabric (checked in knitting section)
Grey fabric inspection section for checking by dyeing dept.
Checking
Ok Not ok
To storage/ batch section Recheck
Dyeing If not ok, Rejection
Checking Standard: Varies depending on buyers’ requirements.
For H&M – 4 point system is followed.
For others – 10 point system is followed.
Frequently found faults:
Loop, Hole, Set-up, Needle, brokenYarn-out, Patty , Patta , Contamination, Lycra-out ,Sinker-mark
,Star-mark ,Wheel-mark, Oil-mark, Groove-mark, Needle-mark, Thick-Thin stripe, Wavy Stripe
Knit Dyeing Operation process :
General process for Dyeing
 Auxiliaries are added at 50° C
 Salt added by dosing system ( time : 10-20')
 pH maintained at 6.5-7
 Color dosing at 6O° C for 20'
Exhaustion & Fixation :
 After 30' soda ash added by dosing for 30-35'
 pH checked & maintained at 10.5
 Dye bath is kept at 60° C for 40-60'
 After every 10' the sample is checked fixation occurs during this time.
 Rinse for 10' & the bath is drained.
Checking
Ok Not ok
Checking
Ok Not ok

Knit dyeing faults and remedies

Knit dyeing faults and remedies

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