Southeas t Unive rs ity Department of Textile Engineering Fundamentals of Denim & Faults in Rope Dyeing 14/09/2011 Name : MAZADUL HASAN SHESHIR ID: 2010000400008 Batch: 13th Batch (Session 2009-2013) Department: Wet Processing Technology Email: mazadulhasan@yahoo.com Blog: www. Textilelab.blogspot.com Southeast University Department of Textile Engineering PREPARED BY ©right Southeas t Unive rs ity Department of Textile Engineering  To know about fault of each process .  To know what is the cause of this faults .  To know about remedies of each faults .  Quality improvement of the product .  Fault analysis. Objective of t he project: Fundamentals of Denim & Faults in Rope Dyeing Southeas t Unive rs ity Department of Textile Engineering  Typical denim fabrics are woven from coarse indigo dyed cotton yarn .  They are hard weaving high density fabrics with a high mass per unit area.  Denim is produced more in the world than any other type of cloth .  It is made for a variety of application and in a wide range of qualities and shades.  Even today, classic denim is still dyed with indigo.  It is a special process in which only the surface of the warp yarn is dyed & the weft stays white.  This is why the garment subsequently develops the typical and desired signs of wear. What is Denim ? 14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing Southeas t Unive rs ity Department of Textile Engineering  Drivability excellent  Luster good  Texture cotton, thus excellent for clothing  Absorbency excellent. Looks good wet, clings.  Durability excellent. Stands up to heavy wear and abuse.  Resilience excellent. Tough fabric, stands up to washing.  Flammability Can be treated to be less flammable, but is cotton.  Fabric source Cotton  Examples of end use jeans, skirts, shirts, jackets. Most popular clothing material in the world. 14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing The properties of denim are as follows : Southeas t Unive rs ity Department of Textile Engineering 1. Stone washed a). Single stone washed b).Double stone washed 2. Chambray 3. Fancy with multi color denim 4. Denim with metal effect 5. Elastic denim 6. Printed denim 7. Jacquard patterned denim 8. Denim with fancy yarns 14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing Denim can be classified as follows : Southeas t Unive rs ity Department of Textile Engineering Mostly use type of Denim Fabric  Cotton Serge  Raw Denim  Selvage Denim  Stretch Denim  Poly-D enim  Ramie-Denim 14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing Type of Denim dyeing process :  Indigo rope dyeing process  Indigo one sheet dye slashing  Indigo double sheet dyeing  Loop dye 1 for 6 (continuous dye slashing)  Loop dye 1 for 6 with dyemer (continuous mercerization dyeing and sizing). Southeas t Unive rs ity Department of Textile Engineering Deference between slasher dyeing vs rope dyeing : Slasher Dyeing Rope Dyeing 1. Required less floor space 1. Required more floor space 2. It is a continuous process 2. It is not a continuous process 3. The mercerizing process is easy and simple 3. In Rope dyeing mercerizing is difficult 4. Required less manpower 4. Required more man power 5. The capacity of dye bath is 100 liter 5. The capacity of dye bath is 2500 liter Southeas t Unive rs ity Department of Textile Engineering Flow chart of denim fabric procedure: Ball Dyeing Long chain beamer Sizing Weaving Finishing Ball Dyeing Long chain beamer Sizing Weaving Finishing Southeas t Unive rs ity Department of Textile Engineering Faults in warping: Fundamentals of Denim & Faults in Rope Dyeing Problems Causes Remedies 1. Lot variation 1. Several lot yarn come from spinning mill . 1. Yarn cone must be tested before production . 2. Chain breakages. 2. Irregular maintenance of chain spoke & gear. 2. Proper maintenance & lubrication of the chain gear and spoke. 3. Thermal damages . 3. Improper lubrication. 3 frictional dnun should not be kept in a polished state. [...]... Fundamentals of Denim & Faults in Rope Dyeing S o uthe as t Unive rs ity Dyeing faults: Department of Textile Engineering Problems Causes Remedies 1 Leakage of steam in drying cylinders 1 Not proper working 1 Proper maintenance has to the steam valve done of the pressure valve 2 Wear and tear of rollers 2 If bearing is jamed 2 Lubricant have to use 3 Entanglement of rope 3 Improper working of load cell... oil squeezing roller 3 Pressure has to distribute properly Fundamentals of Denim & Faults in Rope Dyeing S o uthe as t Unive rs ity Continue: Problems 4 Shade variation Department of Textile Engineering Causes 4 Faults in dosing system Remedies 4 Dosing pump,filter, outer have to maintenance properly 5 Broken yarn in tile rope 5 Improper alignment of the yarn in the rope 5 Change the pressure of theguide... Catch cord is not working properly 2 Air pressure of nozzle is insufficient 1 Check catch cord drawing in and its position 2 Air pressure of all nozzles 1 Piston is not working properly 2 Missing gear of slippage of pinion 1 Check piston 2 Check beam gear and beam drive pinion Fundamentals of Denim & Faults in Rope Dyeing S o uthe as t Unive rs ity Department of Textile Engineering Fig: Bent Pick Fig:... Irregular rope 6 Improper alignment of the rope 6 Guide roller has to work properly Fundamentals of Denim & Faults in Rope Dyeing S o uthe as t Unive rs ity Faults in sizing: Problems Department of Textile Engineering Causes Remedies 1 Pressure rollers do not work properly 1 Incorrect shaft adjustment, whipe roller covering, shed closure wrong 1 Shaft adjustment ,Whipe roller covering have to done properly... covering have to done properly 2 Squeezing rollers do not work properly 2 Incorrect shaft adjustment 2 Shaft adjustment have to check Properly 3 Size dust-off 3 Size chemicals are not 3 Size box have to accommodate in a Proper condition properly mixed Fundamentals of Denim & Faults in Rope Dyeing S o uthe as t Unive rs ity Department of Textile Engineering Faults in Weaving: Problems BENT PICK WEFT PATTI... work properly 2 Yarn must be examined before production BAD SELVEDGE 1 Fault in stop motion 2 Faulty RH cutter 1 Check leno stop motion 2 Check proper RH cutter setting OIL DAGHI S o uthe as t Unive rs ity Department of Textile Engineering Fig: Oily Warp Fig: Ball Formation S o uthe as t Unive rs ity Department of Textile Engineering Remark  In this experiment we learn more think about the denim dyeing. .. ity Continue: Department of Textile Engineering Problem Cause Remedies 4 Sprockets are jammed 4 Hydraulic system does 4 Proper lubrication must be done not work properly 5 Irregular movement of the comb 5 It causes breakages or 5 Reduce the hydraulic friction by using lubricants loosening in yarn 6 Tension variation in yarn 6 If speed of warper increase 6 Check the tension of the tension disk Fundamentals. .. dyeing process  It is very helpful our next life to work in the denim dyeing unit  At lest thank to our respected Course teacher to give me the opportunity to work this type of wonderful experiment Reference:  Understanding Textile for a Merchandiser  Envoy Textile Ltd  www.scribd.com 14/09/2011 Fundamentals of Denim & Faults in Rope Dyeing ... Department of Textile Engineering Fig: Torn or Hole at the Temple Fig: Missing Pick Fig: Abrasion Mark Fig: Tight Ends S o uthe as t Unive rs ity Continue Problems Department of Textile Engineering Causes Remedies 1 Cross end problem MISSING PICK TIGHT ENDS 2 Tight heald wires 2 Check freeness of heald wires 1 Wrong feeler timing in Iboard 2 Unsufficient air pressure 1 Check feeler timing in I-board... Weft Patti Fig: Weft Float Fig: Missing End S o uthe as t Unive rs ity Continue Problems WEFT FLOAT MISSING END Department of Textile Engineering Causes Remedies 1 Air pressure Variation 2 Damage of air pipe 1 Check Air pressure 2 Check leakage of air pipes 1 Serrated bars are loose contact 2 Dropper sensitivity is not working properly 1 Check all serrated bars are not in loose contact at the clamp 2 Dropper . Faults in Rope Dyeing Type of Denim dyeing process :  Indigo rope dyeing process  Indigo one sheet dye slashing  Indigo double sheet dyeing  Loop dye 1 for 6 (continuous dye slashing)  . dyemer (continuous mercerization dyeing and sizing). Southeas t Unive rs ity Department of Textile Engineering Deference between slasher dyeing vs rope dyeing : Slasher Dyeing Rope Dyeing 1. Required. chain beamer Sizing Weaving Finishing Ball Dyeing Long chain beamer Sizing Weaving Finishing Southeas t Unive rs ity Department of Textile Engineering Faults