Dyeing Faults and their Remedies [Video]

Last updated on August 25th, 2023 at 11:04 pm

Dyeing is the most technical part of the Textile Industries. Because you need to match the pre-production sample and production samples shade with buyers approved sample shade and it’s not an easy job. In some cases shade doesn’t match and you need to re-dye the whole batch and in some cases, the following dyeing faults occur:  

Uneven Dyeing 

Causes

  •  Due to improper pretreatment.
  •  Very rapid addition of dyes and chemicals.
  •  Lack of controlling dyeing parameters.

Remedies

  •  Check addition of dyes and chemicals are at a steadily increasing rate.
  •  Proper pretreatments.
  •  Check the rope turnover time.
  •  Proper washing after dyeing.
Uneven Dyeing Fault

Running Shade

Causes

  •  Machine loading is higher.
  •  Running at lower nozzle pressure.
  •  High bath draining temperature.

Remedies

  •  Proper cycle time should be ensured.
  •  Nozzle pressure should be accurate.
  •  The bath draining temperature should be moderate.
Running Shade Fault

Crease Mark

Causes

  •  Excessive loading of fabric during dyeing.
  •  Sudden change in temperature during cooling.
  •  Due to lack of synchronization of winch speed and pump pressure.

Remedies

  •  Follow the temperature gradation during the whole cycle of dyeing.
  •  Fabric must be loaded according to loop length.
  •  Maintaining the proper synchronization between the winch speed and pump pressure.
Crease Mark dyeing fault

Pin Hole

Causes

  •  Due to the presence of traces of Fe+ and Cu+ ions in the process bath.
  •  If soda dosing is done at a high temperature then in presence of an oxygen pinhole is created.
  •  Inadequate amount of stabilizer H2O2 bleaching.

Remedies

  •  The water used in dyeing should be free from water hardness.
  •  Soda dosing should be done at a low temperature (not more than 600C)
Pin Hole dyeing problem

Dye Spot

Causes

  •  Improper mixing and dissolving of dyestuff.
  •  Dye bath hardness.

Remedies

  • Mixing and dosing of dyestuffs should be done properly.
  • The water of the dye bath should hardness free.
Dye Spot dyeing fault

Soda Spot

Causes

  •  If soaping start before wash
  •  CaCO3 or MgCO3 in soaping bath
  •  Quick soda dosing

Remedies

  •  Soda particles should be dissolved properly.
  •  After pre-treatment and dyeing, proper neutralization should be done.
Soda Spot dyeing problem or fault

Fly Dye Stains

Causes

  •  If dye is mixed in the dyeing floor then flying dust particles may come in contact with the dissolved dyestuffs.
  •  If the dyeing floor is too dirty.

Remedies

  •  Dyes should be dissolved in a separate drum and in a separate room.
  •  The dyeing floor must be neat and clean.

Trims Shade does not match with the body

Causes

  •  Different types of yarns are used in fabric and trims.
  •  The dye lot is different for trims and bodies.
  •  Improper recipe setting for trims and fabric.

Remedies

  • The same type of yarn, dye lot, recipe, nozzle pressure, uniform distribution to each nozzle etc. should be used for both fabric and trims.
Trims Shade does not match with the body dyeing fault

Softener Marks

Causes

  •  If pH is not maintained
  •  Poor emulsification of softener applied
  •  Inferior quality of softener

Remedies

  • Ensure that the softener is uniformly dissolved in the water
  • Use the right softener and the correct procedure for the application.
  • Maintain the correct pH.
Softener Marks dyeing fault

Barrie

Causes

  • High yarn tension
  • Count variation
  • Mixing of the yarn lots

Remedies

  •  Ensure uniform yarn tension to all the feeders.
  •  Ensure that the yarn being used for knitting is from the same lot.
Barrie dyeing fault

Metamerism

Causes

  • This is because dye class is not the same for all ropes in a batch or when collar/cuff is dyed using dyes from one lot and body fabric is dyed using dyes from different lots.

Remedies

  • To overcome this, one has to choose the same dye class which will give the same shade at least under a primary and secondary light source.
Metamerism dyeing fault

Hand Feel Problem

Causes

  •  Use of harsh metal chemicals for processing.
  •  Insufficient softeners application in dyeing machine.

Remedies

  • It can be easily reduced by demineralization and can be improved by the addition of a softener.
Hand Feel Problem dyeing problem

You may also like: Working Flowchart of Knit Dyeing

Common dyeing problems and remedies video:

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Abu Sayed

He is Abu Sayed, the founder of the blog site Textile Apex. He is a Textile Engineer having 09 years plus practical experience in the Textile and Clothing industries. With a deep love for fashion and a keen eye for detail, he combines his creative flair with extensive knowledge to offer insightful and engaging content to his readers.

2 thoughts on “Dyeing Faults and their Remedies [Video]

  1. Hello! This is my first visit to your blog! We are a team of volunteers and starting a new initiative in a community in the same niche. Your blog provided us useful information to work on. You have done an outstanding job.

  2. Thanks a lot for sharing this with all of us you really know what you are talking about! Bookmarked. Please also visit my web site =). We could have a link exchange contract between us!

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