Addressing Defects in Dyed Fabric Production

The production of dyed fabrics is a meticulous process that demands meticulous attention to various factors to guarantee the final product meets stringent quality standards. This involves tackling issues such as rod wax, the occurrence of undesirable air, and the development of rotten cotton spots. This article will extensively explore defects in dyed fabric production using circular knitting machines, providing valuable insights and recommendations to rectify issues encountered during the manufacturing process. The objective is to present practical solutions for achieving a seamless and high-quality manufacturing process.

Issue 1: Impact from Rod Wax and Specific Yarn

Expert Recommendation:

1. Evaluate the quality of gray fabric and slurry in each weaving factory, addressing concerns like excessive wax.
2. Remove wax before production using methods such as low-temperature dewaxing agents or softening agents.
3. Identify and treat specific yarns before dyeing, such as baking before the dyeing process to prevent color impact.

Issue 2: Formation and Prevention of Bad Air During Dyeing

Expert Insights:

1. Ensure clean singeing to avoid short fluff, which can lead to bad air, especially visible in light-colored fabrics.
2. Exercise caution with materials, especially fluorescent ones, as improper use can result in a layer of black air on the cloth surface.
3. Adhere to appropriate dyeing processes based on the type of dye and color to prevent undesirable effects like dark or discolored cloth.

Issue 3: Reasons and Prevention of Rotten Cotton Spots and Holes

Expert Guidance:

1. Rotten cotton spots often form during oxygen bleaching, influenced by impurities and rust in the bleaching process.
2. Address rusty spots on cloth before oxygen bleaching to prevent hydrogen peroxide reactions leading to rotten cotton spots.
3. Control hydrogen peroxide content, use clean bleaching liquid containers, and ensure the absence of metal impurities for safe and reliable oxygen bleaching.
4. Regularly clean equipment like seuding machines to prevent cotton adhesion and the formation of black macula during singeing.

Preventive Measures:

1. Ensure clean bleaching liquid containers without metal impurities.
2. Use clean and non-rusty soft water to avoid secondary pollution.
3. Address rusty spots on cloth before oxygen bleaching.
4. Implement safe and reliable oxygen bleaching processes with appropriate auxiliaries.
5. Lower hydrogen peroxide content in thin fabric during production.
6. Use wet cloth during oxygen bleaching to prevent intense reactions.
7. Pay attention to cleaning brushes during singeing to prevent cotton buildup and rotten cotton spots.

Taking proactive measures in fabric examination, dyeing processes, and equipment maintenance can significantly minimize defects, ensuring high-quality dyed fabric production. In conclusion, by implementing these preventive measures and addressing specific challenges at each stage of dyed fabric production, manufacturers can significantly enhance the quality and durability of their final products. A comprehensive approach to defect elimination ensures a seamless and efficient manufacturing process, meeting the high standards demanded by the textile industry.