How To Eliminate Defects in Dyed Fabric Production?

How to improve the success rate of one-time color test?

If it is a frequently produced return color, the pre-treatment process must be stable and consistent to ensure that the semi-finished product gross effect, whiteness, and pH value are consistent each time. And the laboratory must make a sample before dyeing each time, and the dyes and chemicals used in different batches must be compared. If there are no problems, the success rate of one-time color test will be high, and even normal production can be carried out without color test (pay attention to the consistency of dyeing production process and machine).

If a new color is produced, the laboratory must make a small sample for confirmation, and the sample must be matched before dyeing. It is best for different samplers to make samples at the same time. If the two people make the same sample prescription, then the first prescription is close, and the success rate of one-time color test will be high.

The origin and strength of the dyes and chemicals used must be determined, and it is not advisable to change theorigin of the dyes and chemicals frequently. Because there are differences in dye quality, color light stability, additives, production process, etc. among different manufacturers, using dyes from different manufacturers will make the first prescription of the return order differ greatly, affecting the success rate of one-time color test.

How to deal with creases in dyed fabrics?

Crinkles in bleached fabrics are more common in high-count, high-density polyester-cotton fabrics and pure cotton thin fabrics. Due to the high hardness of the water used in production, scale is easily formed during steam washing and easily adheres to the cloth guide roller. Long-term production will form scale grooves, making the cloth guide roller uneven, and the fabric will easily wrinkle. Once wrinkles are found in production, they should be cleaned in time. If wrinkles are found in semi-finished products during dyeing, reasonable processes should be used for repair.

Here are several methods for repairing creases:

If the bleached fabric has uneven temporary creases or mercerized drying creases, if it is relatively light, it can be dyed directly without considering the impact on dyeing. If it is relatively heavy, it can be dyed and produced as long as it is pre-shaped. If there are obvious creases in the bleached fabric, there will be black creases when the fabric is dyed without damaging the fabric. If the creases cause fabric damage, there will be a white crease mark when the fabric is dyed. For this kind of creases, high-temperature over-width stretching and mercerizing are used for repair.

If the dead folds of the bleached cloth are serious and the creases on the cloth have formed aurora marks, this kind of folds is difficult to deal with. The cloth can only be subjected to high-temperature ultra-widening and then lightly sanded to smooth the aurora marks on the folds, and then re-boiled and bleached to make the damaged fabric fibers swell and repair, and finally flattened by high-concentration alkali mercerization.

For the repair of folds, the cause of the folds must be accurately determined first. Different folds have different prevention methods to avoid waste caused by unnecessary processes. For example, mercerized drying folds are easier to find, and they should be dealt with in time after discovery. Don't leave the problem to be fixed before dyeing. If the drying folds are difficult to deal with, you can roll the shaft when the mercerized cloth falls, so that the drying folds are flattened and the folds are ironed with the residual heat of the falling cloth, which can save the time for fixing before dyeing.

How to deal with singed folds?

When dyeing, there are double or multiple black folds on the cloth after padding the dye, and there are fluffy white strips next to the black folds. This kind of fold is a singed fold. After baking, this kind of pleats will show white marks, and after the color is restored, they will become dark black pleats. Singeing pleats are caused by the uneven surface of the fabric during singeing. When the fabric passes through the fire mouth, the high temperature of the fire mouth will burn the place where the pleats are formed. Since the creases cannot be burned inside, white strips of hair are left next to the black pleats.

To prevent singeing pleats, first of all, pleats should not appear during singeing, and a reasonable production process should be formulated according to different fabrics. For thick fabrics, they should be piled or boiled before singeing, so that the singeing will be flattened into the fabric and the possibility of singeing chasing pleats will be reduced. Another thing is to use wet cloth for singeing to prevent the high temperature of the cloth from aggravating the formation of pleats.

If singeing pleats are found during dyeing, they must be repaired before dyeing. Once the machine is started rashly, the black pleats after production and dyeing will not be handled. The method of pre-treatment and repairing singeing pleats is very simple. As long as the high temperature is set to flatten the fabric surface and then singe it, low-alkali mercerization can eliminate the singeing pleats.

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