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Welcome To
Our Presentation
Controlling points, Faults, Causes and Remedies Involved in Different
Finishing Processes of Knit Fabric
Topic
SUPERVISING FACULTY:
RAJIB SAHAASSISTANT PROFESSOR
DEPARTMENT OF TEXTILE ENGINEERINGSOUTHEAST UNIVERSITY
NAME ID NUMBER
IMRAN HOSSAIN 2009000400079
MD.SAIFUDDIN KHAN 2009000400034
Faruk Ahammed 2009000400007
TANZIR 2009000400016MD.AMINUL ISLAM 2009000400104
Prepared By
MD.SAIFUDDIN KHAN
2009000400034
In textile manufacturing, finishing refers to the processes that convert the woven or knitted cloth into a usable material and more specifically to any process performed after dyeing the yarn or fabric to improve the look, performance, or "hand" (feel) of the finished textile or clothing. The precise meaning depends on context.
Introduction
To improve the appearance of the fabric, To improve the feel of the fabric by softening,
stiffening, etc. To improve wearing qualities of cloth by making it
shrink resistant, crease resistant or free from pills and soiling.
To make garments hold their shape and enable them to be worn without ironing.
To impart special properties to the fabric for specific end uses.
To set the texture of certain fabrics and make others dimensionally stable.
To produce stronger and more durable fabrics.
Objects
Classification
Mechanical
Chemical
Temporary
Permanent Or
Durable Temporar
yPermanent Or Durable
Calendaring Raising Starchin
g
Finishing
Resin, Softening,
Mercirization, Water
Repellent.
For Tubular Form:Hydro-extractor
↓ De-watering
↓ Dryer
↓ Tube compactor
Flowchart of machines used for Finishing of Knit fabric
For Open Form : Hydro-extractor
↓ De-watering
↓ Dryer
↓ Slitter
↓ Stenter
↓ Open Compactor
Functions:To extract water from fabric. It is used for collar, cuff, and when fabric
quantity is low.
Controlling point:Speed
Hydro Extractor
Faults Causes Remedies
Crease Mark
Damp fabric moving at high speed in twisted form, in the Hydro
extractor (Centrifuge)
Use anti Crease, during the Scouring & the
Dyeing process (The use of anti Crease,
swells the Cellulose & prevents the formation of
Crease marks) Spread the fabric in loose
& open form & not in the rope form, in the Hydro
Extractor.
Hydro Extractor
Faruk Ahammed
2009000400007
Function: To remove excess water from the fabric,
about 70-75%.Facilates the use of softener.
Controlling points:SpeedPadder PressureBallooning
Dewatering
Faults Causes Remedies
Wet Squeezer Marks
These marks are caused due to the excessive pressure, of the squeezer rolls of the Padding Mangle, on the wet fabric
Use the Padding mangle, only for the application of the softener.
Use a hydro extractor (Centrifuge) for the extraction, to avoid the squeezer roll marks.
Soon after extraction, open the fabric manually, to prevent crease marks in the damp fabric.
Softener Mark
Improper mixing of the Softener.
Improper running time of the fabric during application of softener.
Entanglement of the fabric during application of softener.
Maintaining proper reel sped & pumps speed.
Proper Mixing of the softener before addition.
Prevent the entanglement of the fabric during application of softener.
Dewatering
Function:Slit the tube fabric into open fromRemove excess water from fabric about 70-
75% waterControlling points:Slitting pointSpeedPadder PressureBallooning
Slitting Machine
Faults Causes Remedies
Crease mark If ballooning is not
controlled
Proper ballooning of the fabric should be controlled by air flow before it passes through padder
Softener spot
If softener solution is not properly prepared.
If padder roller is not properly cleaned.
Softener solution should properly be prepared.
Padder roller should be cleaned properly.
Improper slitting Slitting is not done
following the slitting mark.
Observe whether sensor /operator is working properly.
Slitting Machine
Function: To dry the fabric Both open & tube form fabric can be dried
here Mainly GSM highly fabric is dried.
Controlling points: Speed Temperature
Dryer
IMRAN HOSSAIN
2009000400079
Faults Causes Remedies
Overheating and Shade Variation.
If speed and temperature of fabric is not properly controlled.
Temperature & speed should be controlled properly.
Dryer
Function: Sometimes used to dry wet fabric Controlled GSM of fabric Controlled Dia of fabric Controlled shrinkage of fabric Controlled Spirality of fabric Item set of synthetic Fabric.
Controlling point: Temperature & Speed:
◦ For curing of pigment dyed fabric
Stenter
Stenter
For Heat Setting
Fabric type Temperature Speed
Lycra 190°c 17-20 m/min
Polyester 185°c 17-20m/min
OverfeedPadder pressureSkew and Bow
Stenter
Faults Causes Remedies
Startch stains and white lines on finished cloth
Starch stains and white lines on the finished cloth are produced because of incomplete dissolution of the starch in the padding liquour.
Fabric should be desized and restarched.
Longitudinal Creases
Longitudinal creases are produced if the cloth passes on non-uniform cylinders after starching.
The cloth should be padded in a solution of hot water and dried on an even surface.
Wrong and narrow width
Frequent stoppages during mercerization or drying produce cloth with non-uniform width.
Cloth should be passed again through the Stenter to get the required width.
Stenter
TANZIR 2009000400016
Faults Causes Remedies
Softener Mark
Improper mixing of the Softener.
Improper running time of the fabric during application of softener.
Entanglement of the fabric during application of softener.
Maintaining proper reel sped & pumps speed.
Proper Mixing of the softener before addition.
Prevent the entanglement of the fabric during application of softener.
Crease Mark
Poor opening of the fabric rope.
Shock cooling of synthetic material.
If pump pressure & reel speed is not equal
Due to high speed m/c running.
Maintaining proper reel sped & pumps speed.
Lower rate rising and cooling the temperature.
Reducing the m/c load.
Higher liquor ratio
GSM variation & width variation for lycra fabric.
Improper heat setting Mention properly heat setting.
Stenter
Faults Causes Remedies
Spirality problem Improper skew control Skewness of the fabric should
be controlled specially for single jersey fabric.
Overheating If temperature and speed is
not properly controlled. temperature and speed should
properly be controled.
Width problem
Improper width setting during stentering.
Improper heat setting of lycra fabric.
Width should properly be set during stentering.
Heat setting should properly be done.
Stenter
Function: Increases G.S.M. of fabricControl dia of fabricCalendar the fabric
Compactor
MD.AMINUL ISLAM2009000400104
CompactorControlling points:OverfeedWidthPadder pressure:
Chart Of Padder Pressure For Different Types of fabrics:Fabric Pressure (lb/inch2)
Single jersey 9-18
1*1 RIB 18-33
Double pique 18-27
Others 18
Faults Causes Remedies
Folding Marks
High pressure of the fabric Take Down rollers of the Knitting machine, on the grey fabric, is one of the main causes.
Too much pressure of the feeding rolls of the Calendar & Compactor is, the primary cause of the folding marks, in the knitted fabric.
Adjust the gap between the two rolls, as per the thickness of the fabric sheet (Pique, S.J. etc.)
Gap between the two Calendar rolls should be just enough, to let the rolls remove, the wrinkles in the fabric, but put no pressure on the fabric sheet, especially in the case of Pique & structured fabrics
Skewing or Diagonal Grain Lines (Wales)
Improper feeding of the fabric, while Calendaring & Compacting.
Keep a slit line on one side of the tubular fabric.
Use the slit line, as a reference line, to keep the grain lines straight, while feeding the fabric slowly, on the Calender, or the Compactor machines
Compactor
Faults Causes Remedies
GSM Variation
Roll to roll variation in the, process parameters, of the fabric, like; Overfeed & Widthwise stretching of the dyed fabric, on the Stenter, Calendar & Compactor machines.
Roll to roll variation in the fabric stitch length.
Make sure that all the fabric rolls in a lot, are processed under the same process parameters.
The Knitting Machine settings, like; the Quality Pulley diameter etc. should never be disturbed.
Compactor
Softening treatment is one of the most important chemical after treatments in the textile industry. By softening treatment textile can achieve not only soft handle but also:
Some smoothness. More flexibility.
Drape and Pliability.
Antistatic properties.
Luster.
Soft handle.
Softener
Types of softeners: There are mainly four types of softeners
which are discussed below: Cationic Softeners.Anionic Softeners.Non-ionic Softeners.Silicon based Softeners.
Softener
Chemical
Softness
Lubricity
Hydro-philicit
y
Substantivity
Stability to
yellowing
None foamin
g
Anionic + ++ ++ – ++ –
Cationic +++ – – +++ – +
Non-ionic
+ – – – ++ +
Silicones
+++ +++ – to + +++ +++ to +
++
Comparison among various properties of different softeners :
Softener
We all have tried our level best in accomplishing the project. Although we know there was a vast chance and field for working with the project but due to some lack of time we came up with best. We are greatly thankful to the management and staffs of the companies namely “MASCO TEXTILES INDUSTRIES”, “NAZ BANGLADESH LTD” AND “PADMA POLY COTTON KNIT FABRICS LTD”. Without their constant support it could not have been possible. In our project we came up mainly with different kinds of finishing faults in different machines and their remedies. We express our heartiest thanks to our project supervisor and honorable teacher, RAJIB SAHA, Assistant Professor of the Department of Textile Engineering for his logical guidelines, constant inspirations, necessary instructions and proper supervision. We could have done much better if we could have gathered more practical based knowledge.
.
Conclusion
First of all, I am grateful to the ALMIGHTY ALLAH for enabling us to complete the project successfully.
I would also like to thank our respected teachers of SOUTHEAST
UNIVERSITY for giving us the opportunity and helping us in all possible ways to finish the project successfully and also for their valuable suggestions. My deepest appreciation goes to our honorable Chairman Professor SYED FAKHRUL HASSAN, Head, Department of Textile Engineering, SEU and A.N.M AHMEDULLAH SIR, CO-ORDINATOR OF THE DEPARTMENT for their continuous encouragement and valuable suggestions. We express our heartiest thanks to our project supervisor and honorable teacher, RAJIB SAHA, Assistant Professor of the department for his logical guidelines, constant inspirations, necessary instructions and proper supervision
A special thanks to all other faculty members for their continuous
encouragement and valuable suggestions all throughout our work.
Thanks Giving
Thanks To All