Controlling points, Faults, Causes and Remedies Involved in Different Finishing Processes of Knit Fabric

2. Topic Controlling points, Faults, Causes and Remedies Involved in Different Finishing Processes of Knit Fabric

3. SUPERVISING FACULTY: RAJIB SAHA ASSISTANT PROFESSOR DEPARTMENT OF TEXTILE ENGINEERING SOUTHEAST UNIVERSITY

4. Prepared By NAME ID NUMBER ID NUMBER 2009000400079 IMRAN HOSSAIN 2009000400034 MD.SAIFUDDIN KHAN 2009000400007 Faruk Ahammed 2009000400016 2009000400104 TANZIR MD.AMINUL ISLAM

5. Introduction 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.

6. Objects To improve the appearanceof 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 resistantor 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 strongerand more durable fabrics.

7. Classification Finishing Chemical Mechanical Permanent Or Durable Permanent Or Durable Temporary Temporary Calendarin g Resin, Softening, Mercirization, Water Repellent. Raising Starching

8. Flowchart of machines used for Finishing of Knit fabric For Tubular Form: Hydro-extractor ↓ De-watering ↓ Dryer ↓ Tube compactor

9. For Open Form : Hydro-extractor ↓ De-watering ↓ Dryer ↓ Slitter ↓ Stenter ↓ Open Compactor

10. Hydro Extractor Functions: To extract water from fabric. It is used for collar, cuff, and when fabric quantity is low. Controlling point: Speed

11. Hydro Extractor Faults Causes Remedies  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.  Damp fabric moving at high speed in twisted form, in the Hydro extractor (Centrifuge) Crease Mark

12. Dewatering Function: To remove excess water from the fabric, about 70-75%. Facilates the use of softener. Controlling points: Speed Padder Pressure Ballooning

13. Dewatering Faults Causes Remedies  Use the Padding mangle, only for the application of the softener.  Use a hydro (Centrifuge) extraction, squeezerroll marks.  Soon after extraction, open the fabric prevent crease marks in the damp fabric.  These marks are caused due to the excessive pressure, of the squeezer rolls of the Padding Mangle, on the wet fabric extractor for avoid the the to Wet Squeezer Marks manually, to  Improper mixing of the Softener.  Maintaining proper reel sped & pumps speed.  Improper running time of the fabric during application of softener.  Proper Mixing of the softener before addition. Softener Mark  Prevent the entanglement of the fabric during application of softener.  Entanglement of the fabric during application of softener.

14. Slitting Machine Function: Slit the tube fabric into open from Remove excess water from fabric about 70-75% water Controlling points: Slitting point Speed Padder Pressure Ballooning

15. Slitting Machine Faults Causes Remedies  Proper ballooning of the fabric should be controlled by air flow before it passes through padder  Softener solution should properly be prepared.  Padder roller should be cleaned properly.  Observe whether sensor /operator is working properly.  If ballooning is not controlled Crease mark  If softener solution is not properly prepared.  If padder roller is not properly cleaned. Softener spot  Slitting is not done following the slitting mark. Improper slitting

16. Dryer Function:  To dry the fabric  Both open & tube form fabric can be dried here  Mainly GSM highly fabric is dried. Controlling points:  Speed  Temperature

17. Dryer Faults Causes Remedies If speed and temperature of fabric is not properly controlled.  Temperature & speed should be controlled properly.  Overheating and Shade Variation.

18. Stenter Function: Sometimes used to dry wet fabric Controlled GSM of fabric Controlled Diaof fabric Controlled shrinkage of fabric Controlled Spiralityof fabric Item set of synthetic Fabric. Controlling point: Temperature & Speed:  For curing of pigment dyed fabric

19. Stenter  For Heat Setting Fabric type Temperature Speed Lycra 190°c 17-20 m/min Polyester 185°c 17-20m/min

20. Stenter Overfeed Padder pressure Skew and Bow

21. Stenter Faults Causes Remedies  Starch stains and white lines on the finished cloth are produced because of incomplete dissolution of the starch in the padding liquour. Startch stains and white lines on finished cloth  Fabric should be desized and restarched.  Longitudinal creases are produced if the cloth passes on non-uniform cylinders after starching.  Frequent stoppages during mercerization or drying produce cloth with non- uniform width.  The cloth should be padded in a solution of hot water and dried on an even surface. Longitudinal Creases  Cloth should be passed again through the Stenter to get the required width. Wrong and narrow width

22. Stenter Faults Causes Remedies Maintaining proper reel sped & pumps speed.  Improper mixing of the Softener.  Improper running time of the fabric during application of softener.  Proper Mixing of the softener before addition.  Softener Mark Prevent the entanglement of the fabric during application of softener.  Entanglement of the fabric during application of softener.  Poor opening of the fabric rope. Maintaining proper reel sped & pumps speed.   Shock cooling of synthetic material.  Lower rate rising and cooling the temperature.  If pump pressure & reel speed is not equal Crease Mark  Reducing the m/c load.  Due to high speed m/c running. Higher liquor ratio   GSM variation & width variation for lycra fabric. Improper heat setting Mention properly heat setting.  

23. Stenter Faults Causes Remedies  Skewness of the fabric should be controlled specially for single jersey fabric. Spirality problem  Improper skew control  If temperature and speed is not properly controlled.  temperature and speed should properly be controled. Overheating  Improper width setting during stentering.  Improper heat setting of lycra fabric.  Width should properly be set during stentering.  Heat setting should properly be done. Width problem

24. Compactor Function: Increases G.S.M. of fabric Control diaof fabric Calendar the fabric

25. Compactor Controlling points: Overfeed Width Padderpressure: Chart Of PadderPressure For Different Types of fabrics: Fabric Pressure (lb/inch2) 9-18 Single jersey 1*1 RIB 18-33 Double pique 18-27 Others 18

26. Compactor Faults Causes Remedies 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 fabrics  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 Compactor is, the primary cause of the folding marks, in the knitted fabric.    Folding Marks Calendar & & structured 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  Improper feeding of the fabric, while Calendaring Compacting.   & Skewing or Diagonal Grain Lines (Wales)

27. Compactor Faults Causes Remedies  Roll to roll variation in the, process parameters, of the 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 settings, like; the Quality Pulley diameter should disturbed. fabric, like; Machine GSM Variation etc. be never

28. Softener 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.

29. 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.

30. Softener Comparison among various properties of different softeners : Chemical Softness Lubricity Hydro- philicity Substant ivity Stability to yellowin g ++ None foaming + ++ ++ Anionic – – +++ +++ + Cationic – – – + ++ + Non-ionic – – – +++ +++ – to + +++ +++ to + ++ Silicones

31. Conclusion there was a vast chance and field for working with the project but due to some lack of We all have tried our level best in accomplishing the project. Although we know 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. .

32. Thanks Giving 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.

33. Thanks To All