Different faults of fabric

Introduction:
Definition of defect:
1. An imperfection that impairs worth or utility.
2. Want or absence of something necessary for completeness or perfection.
3. A fault that spoils the material.
Fabric defect:
A Fabric Defect is any abnormality in the Fabric that hinders its acceptability by the consumer.
Importance of fabric defect:
• Due to the increasing demand for quality fabrics, high quality requirements are today
greater since customer has become more aware of poor quality problems.
• To avoid Rejection of fabric, it is necessary to avoid defects.
• Price of fabric is reduced by 45%-65% due to the presence of defects.
• Company image will go down.
List of fabric defects in woven fabrics:
1. Loose warp in fabric
2. Double end
3. Broken warp
4. Tight end
5. Float of warp
6. Wrong end color
7. Broken pick
8. Miss pick
9. Double pick
10. Loose weft
11. Oil spot
12. Temple pierced hole
13. Thick and thin places

1. Loose warp in fabric
Reasons:
1. If the tension of warp yarn is low in warping, then this fault appears.
2. If the beam contain broken warp yarn.
Remedies:
1. The warp tension in warping should be equal and uniform.
2. We have to motivate the worker to take care of the fabric.
2. Double end
Reason:
After sizing if the two ends of warp sticks together. And if the worker don’t observe that
properly than those ends can go together through the same heald eye and can create this
problem.

Remedied:
Worker have to be very care full about this matters.
3. Broken warp
Reason:
If a warp yarn breaks and if the dropper don’t fall on the dropper bar, then this fault arise.
Remedies:
1. Operator should walk around the machine to observe this sorts of problem.
2. If the problem is in the dropper bar then, we have to change that bar.
4. Tight end
Reason: If the tension of a warp yarn is more than the other ends present in the loom then this
problem arise. This over tension produced on warp during warping and weaving.

Remedies:
To solve this problem we have to find these ends and have to adjust the tension.
5. Float of warp
Reason:
If someone pull the fabric towards the cloth roller intentionally or intentionally then we can have
this fault.

Remedies:
Worker have to be very careful about the button which causes the fabric to come forward.
6. Wrong end color
Reason:
It happens due to the wrong drawing of colour yarn.
Remedies:
1. Worker have to be very careful during doing the job of drawing.
2. After finding the faults we have to remove the faulty colour yarn and place a correct
colour yarn.
7. Broken pick
Reasons:
1. If the speed of the machine is too high, then beat force of the reed to weft yarn will be too
high.
2. If the pressure of the relay nozzle and elca is too high.

Remedies:
1. We have to reduce speed of the machine.
2. We have to reduce the pressure of relay nozzle or elca.
8. Miss pick
Reasons:
If a worker start a stopped machine without picking the broken weft from the shed then this
type of fault arise.
Remedy:
We have to motivate the worker to do job properly during time of pick finding.
9. Double pick
Reason:
If the cutter don’t work properly.

Remedy:
The angle of the cutter should be changed or its blade should be changed.
10. Loose weft
Reason:
1. It happens due to the malfunctioning of the pet.
2. Due to looseness of the filling yarn
3. The wrong alignment of pre-winder to fixed nozzle.
Remedies:
1. The degree of the pet have to be perfect.
2. The pressure of the main valve, relay valve and relay nozzle should be perfect.
3. The alignment of the presider should uniform and straight.
11. Oil spot
Reason:
Oil spot on the fabrics are caused by too much oiling on loom parts from other sources.

Remedy:
This stains are removed scouring.
12. Temple pierced hole
Reason:
If the ring of the temple is damaged then we will have this fault.
Remedy:
The bristle of the temple should be sharp and easy going.

13. Thick and thin places
Reasons:
This comes due to the thick, thin places that presents in the fabric.
Remedy:
The yarn have to be checked by QC during the time of procurement to avoid these faults.

List of fabric defects in woven fabrics:
1. Needle Line
2. Hole
3. Oil Mark
4. Foreign Materials/ Fly
5. Press Off
6. Thick and Thin Place
7. Missing Yarn
8. Lycra Out/Lycra Drop
9. Sinker Line
10. Needle Mark
11. Pin hole

1. Needle Line
Causes:
 Due to defective needle.
 Dirty needle slot.
 Needle too tight or loose in the slot.
 Due to improper lubrication of needles
Remedies:
 Replacing all the defective needles having, bent latches, hooks or stems.
 Removing the fibers accumulated in, the Needle tricks (grooves).
 Replacing any bent Needles, running tight in the tricks.
 Checking the Needle filling sequence in the Cylinder / Dial grooves (tricks).
2. Hole
Causes:
 Due to badly tied knot.
 Needle break due to slub.
 Due to high tension of yarn.

Remedies:
 Ensuring uniform yarn tension on all the feeders, with a Tension Meter.
 Rate of yarn feed should be strictly regulated, as per the required Stitch Length..
 Eyelets & the Yarn Guides, should not have, any fibers, fluff & wax etc. stuck in them.
 The yarn being used, should have no imperfections, like; Slubs, Neps & big knots etc
3. Oil Mark
Causes:
 Due to improper lubrication.
 Fibers & fluff accumulated in the needle tricks, which remain soaked with oil.
Remedies:
 Fibers, accumulated in the needle tricks, cause the oil to seep into the Fabric.
 Remove all the Needles & the Sinkers of the machine, periodically.
 Cleaning the grooves of the Cylinder & Dial of the machine thoroughly.
 Blowing the grooves of the Cylinder, Dial & Sinker ring, with dry air after cleaning.
4. Foreign Materials/ Fly
Causes:
 If foreign materials knit with the yarn

Remedies:
 Blowing the grooves of the Cylinder, Dial & Sinker ring, with dry air during cleaning.
5. Press Off
Causes:
 When all or some of needles on circular knitting fail to function and the fabric either falls
off the machine or design is completely disrupted or destroyed.
Remedies:
 Needle detectors, should be set precisely, to detect the closed needles & prevent the
fabric tube from completely pressing off.
 Proper yarn tension should be maintained, on all the feeders.

6. Thick and Thin Place
Causes:
 Uneven tension.
 Uneven courses.
 Count Mix, lot mix.
Remedies:
 Preventing count or lot mixing.
 Maintaining uniform yarn tension.
7. Missing Yarn
Causes:
 Faulty positive feed system.
 Wrong feeder setting.

Remedies:
 Correcting yarn feeding with proper tension.
 Removing fly from yarn feeding path.
8. Lycra Out/Lycra Drop
Causes:
 Faulty Lycra feeding system
 Lycra Breakage.
Remedies:
 Checking Lycra feeding system.
9. Sinker Line
Causes:
 Due to uneven movement of sinker.
Remedies:
 Replace, all the worn out or bent sinkers, causing Sinker lines in the fabric.
 Sinker lines are very fine & feeble vertical lines, appearing in the fabric.
 Remove the fibers, clogging the Sinker tricks (Grooves)

10. Needle Mark
Causes:
 When a needle breaks down then needle mark comes along the fabrics.
 If a needle or needle hook is slightly bends then needle mark comes on the fabrics.
Remedies:
 Needle should be straight as well as from broken latch.
11. Pin hole
Causes:
 Due to break down or bend of the latch, pin hole may come in the fabric.
Remedies:
 Change the needle.

Conclusions:
• Due to presence of fabric defect, it has to be sold at lower prices, or even in some cases
as seconds, which creates a Hugh value loss to the company.
• To minimize value loss due to variety of defect occurring in the fabric, a manufacturer
should try to minimize those defects by taking suitable remedies.
References:
• Textiles Committee, Ministry of Textiles, “A catalogue on woven fabric defects and
visual inspection”.
• Tamnun E Mursalin, Fajrana Zebin Eishita , Ahmed Ridwanul Islam,”Fabric defect
inspection system using neural network and microcontroller” Journal of Theoretical and
Applied Information Technology, vol 4, july 2008 pp 560-570.
• Circular Knitting (2nd edition) by Iyer , pp 236-239.
• K.L. Mak, P. Peng, K.F.C. Yiu,“Fabric defect detection using morphological filters”
Image and Vision Computing vol 27, 2009, pp 1585-1586
• http://textilelearner.blogspot.com/2012/04/fabric-faults-causes-of-woven-fabrics.html
• http://textilelearner.blogspot.com/2012/04/fabric-faults-causes-of-woven-fabrics.html
• https://en.wikipedia.org
• http://www.scribd.com
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Different faults of fabric

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