project report on fabric faults(arvind mills 2010)
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UTTAR PRADESH TEXTILE TECHNOLOGY INSTITUTE
KANPUR (Formerly Known as GCTI)
11/208, Souterganj, Parbati Bangla Road, Kanpur
GUIDED BY:- MR. VIJAY KUMAR GUPTA(WEAVING MANAGER)
A PROJECT REPORT ON FABRIC DEFECTS Fabric Defect is a serious problem in weaving department which detoriate the quality of fabric and overall production of fabric reduces. DEEPENDRA, DEEPAK, AJAY 7/26/2010
A PROJECT REPORT ON FABRIC DEFECTS 2010
2
AT
ARVIND MILLS LTD.
DIVISION OF ARVIND PRODUCT LTD.
(SANTEJ, AHMEDABAD)
DURATION
15th
June 2010 to 26th July 2010
A PROJECT REPORT ON FABRIC DEFECTS 2010
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SUBMITTED BY-
AJAY KUMAR (TT)
DEEPAK RATHOUR (TE)
DEEPENDRA KUMAR (TE)
UTTAR PRADESH TEXTILE TECHNOLOGY
INSTITUTE, KANPUR (U.P.)
A PROJECT REPORT ON FABRIC DEFECTS 2010
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ACKNOWLEDGEMENT
First of all We are very thankful to our institute (U.P.T.T.I.) for
providing us the opportunity for getting the practical knowledge as well, under the direction of our most respected director Mr. PRAMOD KUMAR Sir. We have got full support & instructions from Mr. M.K. SINGH Sir for the preparation of the project during training. We have also got full support from all professors & lecturers of Our institute.
We are also very thankful to whole Arvind Group for providing us the
best facility & good environment during the training period. We express our gratitude to each & every employee of Arvind Group for their co-operation & their most valuable time.
We would like to express our gratitude towards Mr. Shubhanish
Malhotra sir (Human Resource) for his co-operation. We pay our thanks to Mr. Vijay Kumar Gupta sir, Who gave his valuable time & attention during training. His instructions are very beneficial for getting the practical knowledge.
Last but not the least, We would like to thank other employees also for
their co-operation, guidance & providing useful data, namely Mr. S.A. Bhatiya, Mr. Sandeep Banerjee, Mr. Partha, Mr. Vijay sir, Mr. Deepak Berman, Mr. Prajapati, Mr. Pankaj, & Others.
(THANKS TO ALL)
AJAY KUMAR DEEPAK RATHOUR
Deependra kumar
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INDEX
S.NO TOPIC PAGE NO.
1. MANAGEMENT 6
2. ABOUT ARVIND MILL 7
3. INTRODUCTION 9
4. FABRIC DEFECTS 10
5. FABRIC INSPECTION TEQNIQUES 13
6. ARVIND MILL GRADING SYSTEM 16
7. PREVENTIVE MAINTENANCE OF LOOMS
FOR REDUCTION OF FAULTS 17
8. STUDY OF FABRIC DEFECTS 25
9. THANKING LETTER 58
A PROJECT REPORT ON FABRIC DEFECTS 2010
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MANAGEMENT
(Year of establishment-1997)
founder’s name- Mr. SANJAY LAL BHAI
(M.D./chairman)
Head of departments-
Mr. Pinakin Patel (weaving)
Mr. Kalyan Bhattacharya (Processing)
Mr. Vishwajeet Nanda (Q.A.)
Mr. Suhas Bhise (PPCN & commercial activities)
Others-
Mr. Vijay Kumar Gupta (weaving manager)
Mr. Pankaj Neve (weaving manager)
Mr. Manish (shift officer)
Mr. Deepak Verma (supervisor)
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ABOUT ARVIND LTD.
Lifestyle Fabrics
The Fabric of a Global Society In a world without boundaries, Arvind fabrics are
equally universal in their appeal. Arvind aims to enrich lifestyles globally, inspiring
diverse customers with the beauty of their fabric.
Denim- There are many delightful features of Arvind denim: An annual capacity of 110 million
meters; the position of 3rd largest producer of denim in the world; and an export network
of 70 countries worldwide. Prominent products in this category include ring denim, indigo
voiles, organic denim, bi-stretch denim and fair trade certified denim. This is apart from
regular light, medium and heavy weight denims. They come in various shades of indigo,
sulphur, yarn-dyeds, in 100% cotton and various blends.
With a discerning clientele that includes GAP, VF Corporation, Levi Strauss,
Abercrombie & Fitch, Calvin Klein to name a few, Arvind has to stay fashionably ahead.
Their designers based out of Japan, Europe and USA create trend setting collections for
the season, ensuring that heads keep turning for the Arvind name. Good from the outside
and from within is the hallmark of a good product. Denim from Arvind offers reliability,
quality and value-addition through services like shrink-film wrapping, bar-coded labeling
of rolls, providing washed and unwashed shade blankets with every order, besides faster
documentation. The facilities of Arvind Denim are accredited with ISO 9001, ISO 14001,
OEKOTEX 100, GOTS, Organic exchange standard, FLO for fair trade and Lycra
Assured. The labs are accredited by Dupont, Levi Strauss.
Shirting-
It is one of the most well-known products of Arvind Group, selling at a premium in the
international market. It has an astonishing annual capacity of 34 million meters. Prominent
products within this category include fabrics with non-iron properties, mechanical
finishes, printed fabrics apart from the cotton and cotton blends in Linen, Lycra, Polyester,
Modal, Silk etc. with varieties in yarn dyeds and solids.
Arvind has a unique plant for manufacturing very light weight indigo dyed fabrics in yarn
dyed and solids for top weights. Arvind Shirting has a liquid ammonia based fabric
processing plant and a state-of-the-art print house – a first for India and one of the few in
Asia. The clientele for the product include names like Polo, Ralph Lauren, ESPRIT, GAP,
FCUK, Zara, Pull & Bear, Louis Philippe, Van Heusen, Allen Solly, Color Plus, Parx and
Park Avenue. The plant is equipped for spinning company, lycra and super fine yarn up to
170’s count. This is in addition to an existing state-of-the- art yarn dyeing facility,
A PROJECT REPORT ON FABRIC DEFECTS 2010
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automatic drawing in unit and an automated fabric inspection and packing facility. And if
that wasn’t enough, the division has the largest sampling plant in India for speedy
churning out of desk looms and yardages for customers. Plus, there’s additional support
from an in-house design studio and a team of designers, who in turn get continuous inputs
on latest international trends from designers based in Italy and the UK.
Khaki-
The division provides the finest fabrics in the variants of 100% Cotton, Cotton Rich
Polyester Blend, Cotton Lycra, Cotton Tencel, Cotton Linen, etc to name a few. The
division has an integrated plant with weaving and processing facilities. The most
prominent products in this range include Chinos, Canvas, Ribstop, HBT, Tussore,
Cavalry, Structures and Dobbies. It’s easy to see why the most discerning customers flock
here: The exalted list includes GAP, J Crew, Polo Ralph Lauren, Abercrombie & Fitch,
Banana Republic, Ann Taylor, Liz Clairborne,(US), Marks and Spencer, Pull & Bear,
Benetton, Grotto Gas, Diesel, Debenhams, (UK), Madura Garments, and Color Plus
(India).
To satisfy such quality conscious customers, the khaki division has a testing and Quality
Control Laboratory, and a Product Development Cell, which not only undertakes value-
engineering of the existing products but is also involved in creating new weaves, blends
and dyeing and processing techniques. The plants are certified by OEKO TEX, Lycra,
Teflon. Laboratory accredited by Marks and Spencers, Next, Dupont, Levi’s, INVISTA.
Knits-
Arvind’s knits department has an annual knitting capacity of 10,000 tons. Apart from the
basic knitting capabilities (jersey, pique, rib, and interlock), Arvind has mastered specialty
knitting techniques such as yarn-dyed autostripers, jacquards, and stretch fabric. The knits
vertical has a fabric dyeing capacity of 6500 tons per annum and yarn dyeing capacity of
3500 tons per annum. It has the ability to process both tubular and open-width fabric and
offer specialty finishes like mercerization, singing and various forms of brushing and
peaching. The department also boasts of a state-of- the art print shop equipped with fully
automatic placement printing capabilities.
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INTRODUCTION
One of the main functions of any weaving machine is to produce defect free fabric. The
incidence of defects in the fabric is not only reduces the aesthetic appeal of the woven,
fabric, butt also reduces the net value realization. The incidence of defects also varies
between mill to mill from shuttle to shuttleless looms and depends upon the deficiencies in
the material, machines and man responsible for it’s manufacture.
The operating feature of all shuttles less looms is that the weft is drawn from large fixed
packages, mounted outside the side frame of the looms. Thus, the differences of fabric
defect between shuttles less looms are mainly due to differences in picking mechanism.
But, there are defects which are common for shuttle and shuttle less looms and arising
from two other primary motions, i.e., shedding and beating up and also defects which are
carried forward from the raw materials to different machines of weaving preparatory.
These defects can be reduced through concerted efforts during the various stages of fabric
manufacturing.
In Textile mills the fabric are inspected at the grey state after weaving and again after
bleaching, dyeing / printing and finishing processes. In the grey inspection, the fabric
defects are identified.
The mandible defects are mended and parched. At this stage the fabrics are often diverted
depending upon the frequency and type of defects.
But, there are defects which are common for shuttle and shuttle less looms and arising
from two other primary motions i.e. shedding and beating up and also defects which are
carried forward from the raw materials to different machines of weaving preparatory.
These defects can be reduced through concerted efforts during the various stages of fabric
manufacturing.
Even under the best possible conditions it is not possible to avoid certain defects e.g.
certain floats / smashes. But majority of the defects are avoidable if certain precautions are
taken.
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FABRIC DEFECTS
CRITICAL DAMAGE NON CRITICAL DAMAGE
NON MENDABLE MENDABLE
Bend Pick
Oil Stain
Black Stain
NON MENDABLE MENDABLE
1. Stop Mark Double Pick
2. Abrasion Weft loop
3. Tight Warp Warp loop
4. Reed Mark Double End
5. Wrong Pattern Slough off
6. Temple Crack
The following defects are common for any type of weaving machine : -
FABRIC DEFECTS ATTRIBUTABLE TO SPINNING –
1. Coarse end / pick
2. Fine end / pick
3. Slubs
4. Slubby / uneven yarn
5. Hairy yarn
6. Snarls
7. Neps
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8. Stains / contamination
FABRIC DEFECTS RELATED TO THE DOUBLING –
1. Single yarn
2. Untwist / less twist yarn
3. Neppy / Fluffy yarn
4. Snarl
5. Stains
6. Knots / tail ends
7. Uneven singing / singing related faults
8. Uneven twist setting .
FABRIC DEFECTS RELATED TO WINDING PACKAGE FAULTS –
1. Slough off
2. Gouts
FABRIC DEFECTS RELATED TO WEAVING PREPARATORY –
1. Sizing patches
2. Pulled warp
3. Multiple breaks
4. Sizing stains
5. Wrong pattern / Drawing in
6. Gouts
7. Sticky ends
8. Mixed yarn
9. Loose selvedge
10. Missing ends
11. Hairy yarn
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TYPES OF DEFECTS
Defects are of three types :
1). Minor Defects :
Slubs
Gout
Stain
Color Fly
Mending impressions
Snarls etc.
Sticker
Tear drop
2). Major Defects :
Broken picks
Missing picks
Thick place
Starting mark
Crlerk
Coarse / fine pick
Wrong weft
Uneven weft
Missing end
Size patches etc.
Stains
Temple Mark
3). Cut Table defects :
Big crack
Float
Hole
Bad selvedge
Reed mark
Less / more picks
Missing ends ( more than 1.25 m )
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FABRIC INSPECTION TECHNIQUES All fabric grading procedure is following by Four Point American System.
POINT COUNT PROCUDURE:
Sr. No. Damage Length Point Count
1.0 Weft Wise
1.1 0.1” to 3” 01
1.2 3” to 6” 02
1.3 6” to 9” 03
1.4 9” to above 04
2.0 Warp Wise
2.1 1/25th of the length 04
3.0 Partial Defect
3.1 =<5 mm 02
Note :-
All colour foreign Matter should be removed.
All Partial Defect More than 5 mm should be cut.
No piece is allowed 4 points defect at beginning 03 Mtrs and Ending 03 Mtrs.
Quality /Grading (for minimum 5000 mtrs shipment)
1) POINTS PER PIECE 2) POINTS PER SHIPMENT
15 POINTS PER 100 SQ. MTRS 12 POINTS PER 100 SQ. MTRS
RECOGNITION OF DEFECTS FOR CHECKERS
Specification &
Appearance
WEAVING RELATED
DAMAGES
COVER Ball Formation
Black Stain
Broken End
Broken Pick
Bump Mark
Broken Pattern
Design Change
Design Cut
Double End
Double Pick
Double Weft
Fine End
Snarling
Stain
Loose Pick
Temple Cut
Temple Mark
Thick & Thin
Weft Bar
Weft Distortion
Wrong Denting
Wrong Drawing
Wrong pattern
Wrong Weft
Bumping
Reediness
Neppiness
Hazyness
Unevness
Streakiness
Kitty Level
Fringe – Less than 4 mm
Selvedge – 6 mm to 8 mm
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Hanging Thread
Starting Mark
Thin Places
Thick Place
Knots
Lashing In
Leno Cut
Less Width
Let off Mark
Light Starting Mark
Light Thick Place
Loom Fly
Loops
Loose Leno Binding
Mending Impression
Missing End
Nozzle mark
Oily Stain
Pulled Warp
Reed Cut
Selvedge without Leno
Short Pick
Sizing Patches/ Crystal
Sizing Stain
Slack End
Slough Off
Slackness
Yarn Lot Change
Reed Mark
Take off Mark
Dobby Line
Jumping End
Floating
Wrong End
DYEING RELATED
DAMAGES
Patta
Shade not matching
Shade Variation
Uneven dyeing
Streaks
PARTIAL DEFECT
SPINNING RELATED
DAMAGES
CRACK
HOLE
FLOA
KNOTTING
MULTIPLAL
BREAKAGE
RUST STAIN
SIZING MACHINE
STOP (S.M.S.)
TORN FABRIC
TEAR DROP
STITCHES
Coarse Pick
Cockled Yarn
Colour Contamination
Count Variation
Dirty End
Double Weft
High Twist Yarn
Knots
Moisture Effect
Neps
Oily Weft
Slub
Slubby Weft
Uneven Weft Yarn
Three Ply
Coarse end
The Following System will be adopted for grading and packing of our grey fabric
:-
1. Inspection Method:- The 100% cloth will be inspected as per four point
American Systems on inspection machine at the speed of 16 to 18 mtrs / minute
2. Fabric Gradation:-
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Marketing /
Grade
Pts/100 sq.
Mtr.
Pts/100 Lnr.
Mtr/
Normal
Width
Pts/100 Lnr
Mtr.
Wider Width
Fabric Length
“A” 15 Points 24 Points 45 Points >= 20 Mtrs &
above for
domestic
>=40 Mtrs &
above for
export
“B” 22 Points 35 Points 67 Points >= 20 Mtrs &
above
“C” 31.25 Points 50 Points 95 Points >= 20 Mtrs &
above
“D” (Cut
Pieces)
No Bar NO Bar (> 1
Mtrs to <10
Mtrs)
NO Bar ( >1
Mtrs to > 5)
>= 1 Mtrs to
=< 10 Mtrs
“E” (Cut
Pieces)
No Bar No Bar (>11
Mtrs to <20
Mtrs)
No bar ( >5
Mtrs to > 20
Mtrs)
>= 11 Mtrs to
< 20 Mtrs
“F” GRADE All continuous
Defect (Warp +
Weft)
NO Bar All continuous
Defect (Warp +
Weft)
>20 MTRS
AND ABOVE
“G” GRADE 47 Points 75 POINTS NILL >20 MTRS
AND ABOVE
Note: All remaining qualities less than one mtrs will be designated as under :-
Market Length Packing
Chindi 0 Cm to 25 Cm In Kg
Fents 25 Cm to 99 Cm In Kg
1. FORMULA
Total Points x39.37x100
Width / Total Mtrs = Points per 100 Sq. Mtrs.
2. FORMULA
Step-1 --- Width /39.37 = Width in Mrs.
Example – 120/39.37 = 3.04
Step- 2 ---
Points / 100 Sq. Mtrs
Total Poits / Total Mtrs/WIDTH. = Points per 100 Sq. mtrs.
Example – 45/100/3.04 WIDTH IN MTRS = 15 Points per Sq. Mtrs.
Note: All fabric will be packed as grade wise only.
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3. Folding/ Plaiting:- Fabric cut looking is done on inspection m/c in roll form at
time of inspection.
4. Folding plating m/c for normal & wider width having for future reference as per
customer demand.
5. Packing:- As per customer requirement
IN ARVIND INTERNATIONAL MILL
4 POINT SYSTEMS
0 - 8 CMS : 1 POINTS
9 - 16 CMS : 2 POINTS
17 - 24 CMS : 3 POINTS
ABOVE 24 CMS : 4 POINTS
NOTE:-Per 100mtrs only four 4 points damage is allowed.
Maximum points 32/100 Lmt(Linear meter)
Grading:- 4Point : 4Places in 100mtrs (A)
4Point : 5Times in 100mtrs (B)
4Point : 6Times in 100mtrs (C)
M. & S. STANDARD 6 POINTS SYSTEM
0 - 25 CMS : 1 POINT
26 - 50 CMS : 2 POINTS
51 - 75 CMS : 3 POINTS
76 - 100 CMS : 4 POINTS
101 - 125 CMS : 5 POINTS
ABOVE 125 CMS : 6 POINTS
Maximum Points 26/100 sq. Mtrs(32/100 LMts)
Maximum 1 Point per 100 sq. Mtrs -7.5 Avg.
Maximum 1 Point per 100 sq. Mtrs - 5 Avg. (22/100 LMtrs)
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1. PREVENTIVE MAINTENANCE OF LOOMS FOR REDUCTION OF
FAULTS
Today cloth quality standards are rising. Unless the loom is in top condition it is
impossible to get consistent high quality of performance.
CLOTH QUALITY LOSS
In respect of quality, following problems are usually due to poor maintenance of looms :
Broken Picks / Mispicks
Starting Marks
Let-off Marks
Slough-off
Oil Stains or streak in fabric
PREVENTIVE MAINTENANCE
Sulzer documents contain following schedules :
Oiling
Monthly Maintenance
Six-monthly Maintenance
OILING & LUBRICATION
It is to be carried out by a person given a small briefing by the technical staff. It is
essential that oil and grease should reach the part which they are intended to lubricate. The
staff should monitor it regularly.
MONTHLY MAINTENANCE
It involves removal, cleaning and % checking of regular parts of the picking and receiving
side. Knowledge of machine and understanding of procedure is a must. Worn out parts can
be changed.
SIX-MONTHLY MAINTENANCE
It implies to carry out a through check as Sulzer recommendations and checklist. It
requires proper training & experience of technician as well as monitoring by staff.
Good maintenance practices are easily adaptable and can systematically be practiced. All
unit owners should recognize the need for the same & implement with all diligence.
2. IMPROVING WEAVABILITY
Improving weavability means making fabric defect free & looms end breakage free. The
Weavability of the warp yarns produced from same raw material can be improved by
changing spinning parameters, spinning technology & to some extent by choice of
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winding parameters. However the yarn must have a certain minimum quality. Besides this,
the weavability can be substantially improved by making a choice of suitable size
materials and size process.
FACTORS AFFECTING WEAVABILITY
GREY YARN QUALITY
FIBER TYPE
The type of fiber affects yarn packing density, nature of yarn surface, yarn cohesion, inter
fiber friction etc. & thereby weaving performance. Short fibers lead to more yarn
breakage.
YARN QUALITY
It depends upon raw material, spinning technology, process parameters, machine
conditions & climate conditions. The first three factors mainly decide yarn structure. They
reflects yarn tensile properties, abrasion resistance, frictional properties, hairiness and
unevenness and yarn faults.
SPINNING TECHNOLOGY
It decides yarn structure & nature of the yarn surface which in turn influence yarn
performance during weaving. Ring spun yarn has highest strength & elongation followed
by rotor & Dref-3 yarns. Dref-3 yarns have the best appearance in spite of high hairiness
followed by ring and rotor yarns. For successful weaving of a warp yarn minimum
strength value is necessary to sustain weaving stresses.
YARN PROCESS PARAMETERS
Yarn structure can be altered to some extent by changing process parameters such as twist,
which decides packing density, migration, fiber extent etc. This in turn is reflected in yarn
properties and yarn behavior. In case of rotor yarn, abrasion resistance increases as twist
factor increase. This reflects in yarn properties, yarn tenacity, breaking extension and
abrasion resistance.
MECHANICAL CONDITION OF SPINNING MACHINE & CLIMATIC
CONDITIONS
They influence end breakage during spinning. This in turn affects yarn faults due to
excessive knotting and thus creates fabric faults.
WARP PREPARATION
EFFECT OF WINDING
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Majority of yarn breaks and fabric defects are caused due to lumps on the yarn such as
knot tails, slubs, neps or other protuberances which affects movement of adjacent yarns
during shed change. If these faults persist during opening of shed, tension in these yarns
becomes abnormally high leading to short picks. So it is necessary to remove these thick
places. But every thick place is replaced by another fault called knot or splice as they are
thicker than parent yarn. So the knot should have least resistance to slippage and minimum
possible length of tails ends.
EFFECTS OF WARPING
The warpers beam should be of uniform density, with no cross slack, or broken ends. Also
warp stops should be less for satisfactory weaving.
EFFECT OF SIZING
Yarn abrasion resistance is affected not only by the yarn properties but also by the type of
sizing agent employed. The abrasion resistance is dependent on the cohesion of the fibers
and the adhesive power of sizing agent. The sizing agent forms a film, which is flexible
joint between the fiber. The extensibility of this film should not be too low, as it has to
follow the extension of the yarn on the loom. Also stickiness & softness of this film is
undesirable. Besides the other variables which affects warp breakage at weaving are :
Yarn Structure
Sizing conditions
Machine conditions
Size recipe
EFFECT OF WEAVING CONDITIONS
EFFECT OF FABRIC PARAMETERS
Various fabric parameters which affect fabric faults and warp breakage also are reed count
and end density. Basic yarn tension plays a vital role in deciding proper weavability.
Increase in basic tension causes increase in abrasion subsequently.
LOOM CODITIONS
Warp stresses and strains can be divided into :
Cyclical yarn pulling force
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Bending and friction forces at deflections
Abrasion and friction
Threads getting caught and tangled.
The third and fourth can be removed by improving sizing and by improving design of
weaving machine. However first and second are unavoidable as they depend on loom
motions like let-off, take-up, back rest position, back rest motion, heald frame motion and
movement of cloth. An appropriate size of shed can reduce warp breakage rate and also
fabric faults.
EFFECT OF CLIMATE CONDITIONS
Increase un humidity generally lowers the warp breakage rate. Changes in the temperature
are least effective than relative humidity changes, which affect warp breakage rate
substantially.
3. YARN QUALITY REQUIREMENTS FOR SHUTTLE LESS LOOMS
Shuttle Less looms are capital intensive. The techno-economics of these machines require
that their productivity should be high and only fault free high value fabrics can be
produced on these machines.
For them to be cost-effective, machine efficiency should be 90%. It increases with
reduction in the time of machine stoppages.
SUGGESTED VALUES OF YARN QUALITY REQUIREMENTS FOR RAPIER AND
PROJECTILE LOOMS
COUNT
YARN QUALITY 40s 60s 80s
1. Yarn Quality 18.00 20.00 20.00
2. CV% of RKM 8.5 9.00 10.00
3. Breaking Elongation 5.25 5.00 4.70
4. Imperfections Per Km 125.00 150.00 300.00
4. FABRIC DEFECTS ATTRIBUTABLES FROM SPINNING TO WEAVING
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The faults in fabric do not occur just due to weaving. They can be traced back to spinning,
post spinning ( Doubling ), winding as well as weaving preparatory also. Any anomaly in
the product of any of these processes result in the fault of the fabric. The various
attributable to the various processes are as follows :
FABRIC DEFECTS DUE TO SPINNING :
Spinning influences majority of yarn properties like abrasion resistance, tensile strength,
hairiness properties, yarn tenacity etc. that is why many fabric faults are traceable to
spinning like :
Yarn count variation in fabric
Slubs
Hairy yarn
Snarls
Neps
Stains / Contamination
Due to count variation, the dye uptake of fabric is changed. Hence patches are formed in
the fabric during dyeing. Slubs, snarls and neps cause uneven thickness of the fabric.
Hairy yarn creates problem in wet processing while stains reduce the value of the fabric.
FABRIC DEFECTS RELATED TO POST SPINNING / DOUBLING
Doubling is a process of twisting two yarns together. Plied and corded both type of yarns
come under this category. It affects yarn properties like twist level in he yarn and knots in
the yarn. Doubling should ensure that there should not be longer lengths of untwisted
yarn. Also there should be smaller lengths of tail ends of knots. The main faults related
with post spinning are as follows :
Untwisted yarn
Lesser twisted yarn
Long tail ends
Uneven twist setting
Short tail ends and hence slipping of knots.
Uneven twisted yarns lead to differential dye take up and also differential tensile
strengths. Longer tail ends of knots entangle in the shed and hence cause end breakage.
Slipping of knots lead to breaking of warp and hence cause frequently loom stoppages.
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FABRIC DEFECTS RELATED TO WINDING
Winding is the first preparatory process of weaving department. It is aimed at producing
long length of fabrics with reduced faults or rather no faults at all, a condition difficult to
achieve. It is very important process as it saves a lot of cost in warping and weaving
department. The main fabric defects attributable to winding are :
Slough off
Gouts
FABRIC DEFECTS RELATED TO WEAVING PREPARATORY
Warping and sizing are the main processes of weaving preparatory. Also drawing in is an
important step before beam gaiting. Warping requires proper attention as the incidence of
cross ends and lappers reduces fabric quality as well as increases the incidence of loom
stoppages due to warp breaks. Even sizing requires attention a man defects are created due
to uneven size take-up as well as wrong size adds-on percentage. In drawing in proper care
is required as wrong denting also creates many fabric defects. The main defects due to
weaving preparatory are :
Sizing patches
Pulled Warp
Sizing stains
Sticky ends
Wrong patterning
Loose selvedge
Missing ends
Hairy yarn
FABRIC DEFECTS RELATED TO WEAVING
In weaving, loom condition as well as loom settings have a great impact on the quality of
fabric. Even under best possible conditions it is not possible to avoid certain defects like
floats, smashes, etc but majority of the defects are unavoidable if certain precautions are
taken. Fabric defects can be classified into three groups – Avoidable and Unavoidable,
Minor and Major and Mendable and Unmendable. The major fabric defects related to
weaving are :
Missing end
Missing pick
Warp streak / reed mark
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Readiness
Bad selvedge
Weft crack
Crammes / Double pick
Thick and thin places
Dropped pick
Weft bars
Stitches or bumping marks
Temple marks
Weft stop motions, weft fork motions and warp protectors are used to detect and trace
weft and / or warp to avoid ant type of cracks in the fabric. Slub catches on the principles
of capacitance and photo electricity are used to detect ant think / thin places. Measuring
motion on unconventional looms is an effective way of controlling the length of pick. Also
specialized nozzles in air-jet and water-jet control motion of the weft very effectively.
5. CONTROL OF FABRIC QUALITY AT LOOM STAGE
The two aspects of fabric quality in the loom shed are :
Meeting the design specification of fabric
Ensuring that the fabrics are free from defects that originate during weaving.
DESIGN SPECIFICATION
In order to make the fabric as per the design specifications, the following factors should be
checked :
Type of fibers / yarns used
Count and twist of warp and weft
End and pick density
Weave and colour pattern
Width of fabric at the reed
A PROJECT REPORT ON FABRIC DEFECTS 2010
24
Gray width of fabric
Length of a cut
FIRST PIECE INSPECTION
After gaiting the beam, all the above mentioned parameters excepting the last one should
be checked at the loom stage by supervisors and jobbers. Additionally the first piece from
the newly gaited loom is taken to gray folding departments and is inspected for design
specifications. The first piece report should be immediately sent to the weaving
department. If the piece does not confirm to the require standard, necessary changes
should be carried out and the next piece should again be sent for inspection.
WEAVING DEFECTS
The first point to be noted is that the quality of the fabric at the loom is dependent by the
entire sequence of operations from weaving preparatory to weaving. The approach should,
therefore, be to consider each process in relation to the manner in which it affects which
subsequent process and not in isolation. In this context, it should be remembered that
though the preparatory departments and loom shed both contribute substantially to the
fabric quality and loom productivity. The conversion at the loom shed is greater than that
of preparatory and so maximum emphasis should be given to the quality of preparation at
the preparatory rather than its .
GREY INSPECTION
Grey inspection is the examination of the fabric after weaving. There should be a
continuous liaison between the gray cloth inspection and weave loom personnel. Looms
constantly giving defects like missing ends, cracks, thin places, wrong drawing, double
ends, defective pattern, etc. can be immediately rectified by strict inspection programme.
It ids recommendation that 100% inspection should be followed at gray stage.
A PROJECT REPORT ON FABRIC DEFECTS 2010
25
STUDY OF LOOM STOP MARK(LSM)
1.
LOOM PARTICULERS:-
Loom No. 623
Loom Type JAT 710
Loom rpm 800
Fabric Type Shirting
Warp Count 60s
Weft Count 60s
Ends / Inch 172
Picks / Inch 96
Reed Space 64.5 inch
Reed Used 171.8
Denting Order 3 ends/dent
No. of Healds 8(capacity 16)
Shedding Type E-Dobby Shedding
Warp Tension 220 Kg-F
Shim Used 4 mm
Weave Dobby
LOOM STOP MARK SETTING:-
ICS SETTING:- S.NO. CHECK POINT SETTING
1. Warp × Weft 60×60
2. Beam Dia 440mm
3. Drawing width 162.8cm(act. 160cm)
4. Measuring Band mark 16
5. Number of sub nozzles 28
6. T0-Tw 90-240
7. WF1 Sensitivity 6
8. Main Pressure 400kPa
9. Sub Pressure 450kPa
SAMPLE
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MECHANICAL SETTING:-
Back
rest
Height
&
Depth
0 – 6
WSM
Height
-1
Easing
Amount
&
Timing
3 – 300o
Heald
frame
Height
&
Amount
S.No.
Height
Dwell
Cross
angle
B.R*
Cross
angle
A.R.*
S. No.
Height
Dwell
Cross
angle
B.R*
Cross
angle
A.R.* 1. 104 0/30 300 330 5. 100 0/30 290 330 2. 102 0/30 300 330 6. 98 0/30 290 330 3. 100 0/30 300 330 7. 96 0/30 310 320 4. 98 0/30 300 330 8. 94 0/30 310 320
*B.R.=Before repairing; *A.R.=After repairing
LSM SETTING:-
S.NO. DELTA SETTING WEFT STOP WARP STOP
1. Running Starting Angle 300 300
2. Running Stop Angle 300 300
3. High speed Starting(Delta) ON ON
4. Motor Acceleration(on starting) AUTO AUTO
5. No weft Beating Pick 0 0
6. Inching Repeat on Starting 0 0
A PROJECT REPORT ON FABRIC DEFECTS 2010
27
S.NO.
SETTING NAME
LET OFF TAKE UP
WARP WEFT WARP WEFT
1. Kick back 0.00mm 0.00mm 0.00mm 0.00mm
2. Shake On Start 0.00mm 0.00mm 0.00mm 0.00mm
3. Times 1 1 1 1
4. Time correction 0 0 0 0
2.
LOOM PARTICULARS:-
Loom No. 663
Loom Type JAT 710 erotech
Loom rpm 880
Fabric Type Shirting
Warp Count 60sC
Weft Count 60sC
Ends / Inch 132
Picks / Inch 88
Reed Space 69 inch
Reed Used 132
Denting Order 2ends/dent
No. of Healds 4(Capacity 8)
Shedding Type Staubli cam shedding
Warp Tension 200 Kg-F
Shim Used 2mm
Weave PLAIN
LOOM STOP MARK SETTING:-
ICS SETTING:- S.NO. CHECK POINT SETTING
1. Warp × Weft 60×60
2. Beam Dia 390mm
3. Drawing width 175.2cm(act.169 cm)
4. Measuring Band mark 24
SAMPLE
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28
5. Number of sub nozzles 30
6. T0-Tw 90-240
7. WF1 Sensitivity 6
8. Main Pressure 300Kg/cm2
9. Sub Pressure 350 Kg/cm2
10. Tension in Kg-F 250
MECHANICAL SETTING:-
Back rest
Height & Depth
0 – 5
WSM Height -2
Easing Amount
& Timing
6 – 300o
Heald frame
Height &
Amount
S.No. Height Amount Dwell Cross 1. 76 138 0/60 310
o
2. 74 140 0/60 310o
3. 72 137 0/60 290o
4. 70 129 0/60 290o
LSM SETTING:-
S.NO. DELTA SETTING WEFT STOP
B.R.*
A.R.*
WARP STOP
B.R.*
A.R.*
1. Running Starting Angle 300o
300o
300o
200o
2. Running Stop Angle 300o
300o
300o
300o
3. High speed Starting(Delta) ON ON ON ON
4. Motor Acceleration(on starting) AUTO AUTO AUTO AUTO
5. No weft Beating Pick 2 0 2 0
6. Inching Repeat on Starting 0 0 0
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29
S.NO.
SETTING NAME
LET OFF TAKE UP
WARP WEFT WARP WEFT
1. Kick back 0.00 0.00 0.00 0.00
2. Shake On Start 0.00 0.00 0.00 0.00
3. Times 1 1 1 1
4. Time correction 0 0 0 0
3.
LOOM PARTICULERS:-
Loom No. 603
Loom Type JAT710
Loom rpm 768
Fabric Type Shirting
Warp Count 60s
Weft Count 60s
Ends / Inch 200
Picks / Inch 100
Reed Space 69 inch
Reed Used 80/5
Denting Order 5 ends/dent
No. of Healds 12 (Capacity 16)
Shedding Type Dobby E- Shedding
Warp Tension 440 Kg-F
Shim Used 2mm
Weave Dobby
SAMPLE
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LOOM STOP MARK SETTING:-
ICS SETTING:-
S.NO. CHECK POINT SETTING
1. Warp × Weft 60×60
2. Beam Dia 520mm
3. Drawing width 175.2cm(act.171cm)
4. Measuring Band mark 24
5. Number of sub nozzles 28
6. T0-Tw 90-240
7. WF1 Sensitivity 6
8. Main Pressure 350 Kg/cm2
9. Sub Pressure 400 Kg/cm2
10. Tension in Kg-F 480
MECHANICAL SETTING:-
Back rest
Height & Depth
12 - 6
WSM Height +1
Easing Amount
& Timing
3 – 300o
Heald frame
Height &
Amount
S.No. Height Amount Dwell Cross 1. 108 mm 48 0/60 300
o
2. 106 mm 56 0/60 300o
3. 104 mm 63 0/60 300o
4. 102 mm 64 0/60 300o
5. 100 mm 75 0/60 300o
6. 98 mm 80 0/60 300o
7. 96 mm 47 0/60 300o
8. 94 mm 52 0/60 300o
9. 92 mm 58 0/60 300o
10. 90 mm 63 0/60 300o
11. 88 mm 67 0/60 300o
12. 86 mm 62 0/60 300o
A PROJECT REPORT ON FABRIC DEFECTS 2010
31
LSM SETTING:-
S.NO. DELTA SETTING WEFT STOP
B.R.*
A.R.*
WARP STOP
B.R.*
A.R.*
1. Running Starting Angle 300o
340o
300o
340o
2. Running Stop Angle 300o
300o
300o
300o
3. High speed Starting(Delta) ON ON ON ON
4. Motor Acceleration(on starting) AUTO AUTO AUTO AUTO
5. No weft Beating Pick 2 0 2 0
6. Inching Repeat on Starting 0 0 0
S.NO.
SETTING NAME LET OFF TAKE UP
WARP WEFT WARP WEFT
1. Kick back 0.00 0.00 0.00 0.00
2. Shake On Start 0.00 0.00 0.00 0.00
3. Times 1 1 1 1
4. Time correction
MARK SETTING:-
S.No. FELL FORWARD WEFT STOP WARP STOP
1. Fell forward amount 0.00mm 0.00mm
2. Shake on Start -3.00mm -3.00mm
3. Times 1 1
A PROJECT REPORT ON FABRIC DEFECTS 2010
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4.
LOOM PARTICULERS:-
Loom No. 621
Loom Type TOYATA JAT 710
Loom rpm 805
Fabric Type Shirting
Warp Count
2/121s
Weft Count 60s
Ends / Inch 162
Picks / Inch 94
Reed Space 64.50
Reed Used 108/3
Denting Order 3 ends/dent
No. of Healds 4
Shedding Type Cam sedding
Warp Tension 240 Kg-F
Shim Used 2 mm
Weave Plain
LOOM STOP MARK SETTING:-
ICS SETTING:- S.NO. CHECK POINT SETTING
1. Warp × Weft 2/121×60
2. Beam Dia 536
3. Drawing width 1631
4. Measuring Bandmark 18
5. Number of sub nozzles 27
6. T0-Tw 90-240
7. WF1 Sensitivity 6
8. Main Pressure 350kPa
9. Sub Pressure 400kPa
10. Tension in Kg-F 240
SAMPLE
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33
MECHANICAL SETTING:-
Back rest
Height & Depth
0-6
WSM Height -1
Easing Amount
& Timing
6-320
Heald frame
Height &
Amount
S.No. Height Amount Dwell Cross 1. 108 0/30 290 2. 106 0/30 290 3. 104 0/30 310 4. 102 0/30 310
LSM SETTING:- S.NO. DELTA SETTING WEFT STOP
B.R.*
A.R.*
WARP STOP
B.R.*
A.R.*
1. Running Starting Angle 300o
320o
300o
320o
2. Running Stop Angle 300o
300o
300o
300o
3. High speed Starting(Delta) ON ON ON ON
4. Motor Acceleration(on starting) AUTO AUTO AUTO AUTO
5. No weft Beating Pick 2 0 2 0
6. Inching Repeat on Starting 0 0 0
S.NO.
SETTING NAME
LET OFF TAKE UP
WARP WEFT WARP WEFT
1. Kick back 0.00 0.00 0.00 0.00
2. Shake On Start 0.00(A.R. -2) 0.00(A.R. -2) 0.00(A.R. -2) 0.00(A.R. -2)
3. Times 1 1 1 1
4. Time correction 0 0 0 0
A PROJECT REPORT ON FABRIC DEFECTS 2010
34
5.
LOOM PARTICULERS:-
Loom No. 616
Loom Type JAT 710
Loom rpm 800
Fabric Type shirting
Warp Count 50s
Weft Count 50s
Ends / Inch 128
Picks / Inch 96
Reed Space 69inch
Reed Used 64
Denting Order 4 ends/dent
Drawing Order 1357
2468
No. of Healds 10
Shedding Type Dobby E-Shedding
Warp Tension 240Kg-F
Shim Used 3mm
Weave Dobby(4/4 Twill)
LOOM STOP MARK SETTING:-
ICS SETTING:- S.NO. CHECK POINT SETTING
1. Warp × Weft 50×50
2. Beam Dia 360mm
3. Drawing width 175.2cm(act.173cm)
4. Measuring Band mark 22
5. Number of sub nozzles 29
6. T0-Tw 90-240
7. WF1 Sensitivity 6
8. Main Pressure 350Kg/cm2
9. Sub Pressure 400Kg/cm2
10. Tension in Kg-F 240
SAMPLE
A PROJECT REPORT ON FABRIC DEFECTS 2010
35
MECHANICAL SETTING:-
Back rest
Height & Depth 0 – 6
WSM Height -1
Easing Amount
& Timing 3 – 300
o
Heald frame
Height &
Amount
S.No. Height Amount Dwell Cross 1. 104 48 300
o
2. 102 56 300o
3. 100 63 300o
4. 98 69 300o
5. 96 75 300o
6. 94 80 290o
7. 92 47 310o
8. 90 52 310o
LSM SETTING:-
S.NO. DELTA SETTING WEFT STOP WARP STOP
1. Running Starting Angle 300 300
2. Running Stop Angle 300 300
3. High speed Starting(Delta) ON ON
4. Motor Acceleration(on starting) AUTO AUTO
5. No weft Beating Pick 0 (A.R. 2) 0 (A.R. 2)
6. Inching Repeat on Starting 0 0
A PROJECT REPORT ON FABRIC DEFECTS 2010
36
S.NO.
SETTING NAME LET OFF TAKE UP
WARP WEFT WARP WEFT
1. Kick back 0.00 0.00 0.00 0.00
2. Shake On Start 0.00 0.00 0.00 0.00
3. Times 1 1 1 1
4. Time correction 0 0 0 0
MARK SETTING:-
S.No. FELL FORWARD WEFT STOP WARP STOP
1. Fell forward amount 0.00mm 0.00mm
2. Shake on Start -3.00mm -3.00mm
3. Times 1 2
CAUSES
1. High rpm of loom.
2. Shim is not correct.
3. Running starting angle is not correct.
4. Back rest height and depth is not correct.
5. Warp stop motion (WSM) height is not correct.
6. Easing amount and time is not correct.
7. Heald frames height and stroke is not correct.
8. Delta and Mark settings are not correct.
REMIDIES
I
st Note down the running rpm of the loom.E.g. 900rpm
Then stop the loom in Filling stop. Re-start the loom. Again stop the loom after 4-5 pick insertion. Go in per pick menu. Check the rpm of the loom after it showing TW=0.E.g.-810rpm Go in ICS/Machine. Feed the rpm found(810rpm). Send the data for RUNSET / DELTA / MARK.
A PROJECT REPORT ON FABRIC DEFECTS 2010
37
Again go in ICS / Machine. Feed the initial rpm(900rpm). Send the data for RUNSET only. Do marking for stop mark for weft and warp stops. Check the for stop mark. If it is OK, then Run the Machine. If it is not then do as given below-
If there is a thick place(patti) at temple only.
1. Set cross angle early.
2. Take back rest down.
3. Reduce easing amount.
4. Delay easing timing.
If there is a thin place (crack) at temple only.
1. Use shake on start(It is must for temple crack.)
If there is a thick place (patti) in whole width.
1. Delay start angle.
2. Set cross angle early.
3.Take back rest up.
If there is a thin place (zirki) in whole width.
1. use no weft beating.
2. Start angle early.
3. Delay cross angle.
4. Take back rest down. Note:-Do not use fell forward and time correction for CLASSICAL SHIRTING
PRODUCTS
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38
STUDY OF BROKEN END
LOOM PARTICULERS:-
Loom No. 625
Loom Type JAR 710 Eurotech
Loom rpm 806
Fabric Type Shirting
Warp Count 40s
Weft Count 40s
Ends / Inch 108
Picks / Inch 68
Reed Space 68 inch
Denting Order 2 ends/dent
Drawing Order 1,2
3,4
No. of Healds 4
Shedding Type Staubli Cam
Warp Tension 240Kg-F
Shim Used 4mm
Weave PLAIN
This defect is caused by broken end woven in the fabric.
MINOR MAJOR SERIOUS
Not Prominent Prominent Not reckoned
CAUSES
Failure of the weaver in attending to the warp breaks properly.
Loose fly in warp.
Defective reed
REMIDIES
The broken end can be removed by using a plucker and the resulting loose threads should
be cut with a trimmer. As a result, a bare patch occurs and combing in both direction with
a metallic comb can mend this.
SAMPLE
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39
STUDY OF BROKEN PICK(BP)
LOOM PARTICULERS:-
Loom No. 607
Loom Type TOYATA JAT710
Loom rpm 720
Fabric Type Shirting
Warp Count 2/82s
Weft Count 60sC
Ends / Inch 162
Picks / Inch 74
Reed Space 63 inch
Reed Used 108/3
Denting Order 3 ends/dent
No. of Healds 6(Capacity 16)
Shedding Type Dobby E-Shedding
Warp Tension 350Kg-F
Shim Used 3mm
Weave Dobby
SAMPLE
A PROJECT REPORT ON FABRIC DEFECTS 2010
40
2.
LOOM PARTICULERS:-
Loom No. 631
Loom Type JAT 710 Eurotech
Loom rpm 850
Fabric Type Shirting
Warp Count 40 MCL
Weft Count 60sC
Ends / Inch 72
Picks / Inch 86
Reed Space 72 inch
Reed Used 72/2
Denting Order 2 ends/dent
No. of Healds 4
Shedding Type Staubli Cam Shedding
Warp Tension 250Kg-F
Shim Used 2mm
Weave PLAIN
CAUSES
1. WF2 sensitivity is low.
2. WF2 detect angle is not correct.
3. WF2 is not clean.
4. Wrong pressure setting.
5. Bolls formation.
REMIDIES
1. Set the WF2 sensitivity as standard.
2. Set the WF2 pulse at 4
3. Do not disturb the detect angle of WF2.
4. Clean the feeler head regularly.
5. Set the pressure as per requirement.
6. Reduce boll formation.
SAMPLE
A PROJECT REPORT ON FABRIC DEFECTS 2010
41
STUDY OF BEND PICK
1.
LOOM PARTICULERS:-
Loom No. 628
Loom Type JAT 710 Eurotech
Loom rpm 800
Fabric Type Shirting
Warp Count 50s
Weft Count 50s
Ends / Inch 120
Picks / Inch 102
Reed Space 71.5inch
Reed Used 80/3
Denting Order 3 ends/dent
No. of Healds 4
Shedding Type Staubli Cam Shedding
Warp Tension 240Kg-F
Shim Used 2mm
Weave Twill
CAUSES
1. Sub nozzles are not aligned.
2. Incorrect pressure setting.
3. Incorrect ABS setting.
4. Catch cord drawing is not correct.
REMIDIES
1. Sub nozzles should be aligned.
2. Pressure should be correct as per requirement.
3. Correct ABS setting.
4. Correct the Catch cord drawing is not.
SAMPLE
A PROJECT REPORT ON FABRIC DEFECTS 2010
42
STUDY OF WEFT CUTS OR REED MARKS
1.
LOOM PARTICULERS:-
Loom No. 621
Loom Type TOYATA JAT 710
Loom rpm 805
Fabric Type Shirting
Warp Count
2/121s
Weft Count 60s
Ends / Inch 162
Picks / Inch 94
Reed Space 64.50
Reed Used 108/3
Denting Order 3 ends/dent
No. of Healds 4
Shedding Type Cam sedding
Warp Tension 240 Kg-F
Shim Used 2 mm
Weave Plain
Loom No. 621
CAUSES
1. Weak yarn in weft is used.
2. Early cross angle.
3. Beam TENSION is more (weft cuts).
4. Beam tension is less (Reed cuts).
5. Dwell is less.
6. Shed angle is more (Weft cuts).
7. Shed angle is lees (Reed cuts).
REMIDIES
1. Change the weak yarn.
2. Delay the cross angle.
3. Decrease the TENSION (weft cuts).
4. Increase the TENSION (Reed cuts).
SAMPLE
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5. Set bigger Dwell.
6. Decrease the Shed angle (Weft cuts).
7. Increase the Shed angle (Reed cuts).
NOTE:-Difference between weft cuts and reed cuts is that weft cuts are at random in full
width of fabric and reed cuts are confined in temple area only.
STUDY OF WEFT LOOPS
1.
LOOM PARTICULERS:-
Loom No. 603
Loom Type JAT710
Loom rpm 768
Fabric Type Shirting
Warp Count 60s
Weft Count 60s
Ends / Inch 200
Picks / Inch 100
Reed Space 69 inch
Reed Used 80/5
Denting Order 5 ends/dent
No. of Healds 12 (Capacity 16)
Shedding Type Dobby E- Shedding
Warp Tension 440 Kg-F
Shim Used 2mm
Weave Dobby
LOOM STOP MARK SETTING:-
ICS SETTING:- S.NO. CHECK POINT SETTING
1. Warp × Weft 60×60
2. Beam Dia 520mm
3. Drawing width 175.2cm(act.171cm)
4. Measuring Band mark 24
5. Number of sub nozzles 28
SAMPLE
A PROJECT REPORT ON FABRIC DEFECTS 2010
44
6. T0-Tw 90-240
7. WF1 Sensitivity 6
8. Main Pressure 350 Kg/cm2
9. Sub Pressure 400 Kg/cm2
10. Tension in Kg-F 480
CAUSES
1. Sub nozzles are not aligned.
2. Incorrect pressure settings.
3. Incorrect To – Tw setting.
4. Cross angle either too early or too delayed.
5. To little staggering.
6. Frame height is not ok.
REMIDIES
If weft loops are at left hand side (LHS)
1. Set correct pressure settings.
2. Reduce the rpm of loom.
3. Set Cross angle delayed.
If weft loops are at Centre
1. Set correct pressure settings.
2. Set Cross angle delayed.
If weft loops are at right hand side(RHS)
1. Align the sub nozzles.
2. Set the Tw early.
3. Set the correct pressure.
4. Increase the beam tension.
5. Correct the catch –cord drawing.
6. Set Cross angle delayed.
A PROJECT REPORT ON FABRIC DEFECTS 2010
45
STUDY OF TEMPLE MARK
1.
LOOM PARTICULERS:-
Loom No. 669
Loom Type JAT 710 eurotech
Loom rpm 900
Fabric Type Shirting
Warp Count 2/101s
Weft Count 50s
Ends / Inch 108
Picks / Inch 92
Reed Space 66 inch
Reed Used 108/2
Denting Order 2 ends/dent
No. of Healds 4
Shedding Type Staubli cam shedding
Warp Tension 250 Kg-F
Shim Used 2 mm
Weave PLAIN
ICS SETTING:- S.NO. CHECK POINT SETTING
1. Warp × Weft 2/101 × 50
2. Beam Dia 480mm
3. Drawing width 167.6cm(act.161cm)
4. Measuring Bandmark 18
5. Number of sub nozzles 28
6. T0-Tw 90-240
7. WF1 Sensitivity 6
8. Main Pressure 400
9. Sub Pressure 450
SAMPLE
A PROJECT REPORT ON FABRIC DEFECTS 2010
46
2.
LOOM PARTICULERS:-
Loom No. 647
Loom Type JAT 710 eurotech
Loom rpm 805
Fabric Type Shirting
Warp Count 60sC
Weft Count 60sC
Ends / Inch 120
Picks / Inch 98
Reed Space 69 inch
Reed Used 120/2
Denting Order 2ends/dent
Drawing Order 1,2
3,4
No. of Healds 4(capacity 8)
Shedding Type Staubli cam shedding
Warp Tension 220 Kg-F
Shim Used 3mm
Weave PLAIN
ICS SETTING:- S.NO. CHECK POINT SETTING
1. Warp × Weft 60×60
2. Beam Dia 556mm
3. Drawing width 175.2cm(act.166cm)
4. Measuring Band mark 24
5. Number of sub nozzles 28
6. T0-Tw 90-240
7. WF1 Sensitivity 6
8. Main Pressure 350kPa
9. Sub Pressure 400kPa
SAMPLE
A PROJECT REPORT ON FABRIC DEFECTS 2010
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CAUSES
1. Temple Ring angle is not correct.
2. Ring type is not correct.
3. Drawing width is more.
REMIDIES
1. Correct the ring style.
2. Correct the inclination of ring.
3. Correct the position of temple.
STUDY OF LESS & MORE PICK
LOOM PARTICULERS:-
Loom No. 663
Loom Type JAT 710 erotech
Loom rpm 880
Fabric Type Shirting
Warp Count 60sC
Weft Count 60sC
Ends / Inch 132
Picks / Inch 88
Reed Space 69 inch
Reed Used 132
Denting Order 2ends/dent
No. of Healds 4(Capacity 8)
Shedding Type Staubli cam shedding
Warp Tension 200 Kg-F
Shim Used 2mm
Weave PLAIN
SAMPLE
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LOOM STOP MARK SETTING:-
ICS SETTING:- S.NO. CHECK POINT SETTING
1. Warp × Weft 60×60
2. Beam Dia 390mm
3. Drawing width 175.2cm(act.169 cm)
4. Measuring Band mark 24
5. Number of sub nozzles 30
6. T0-Tw 90-240
7. WF1 Sensitivity 6
8. Main Pressure 300Kg/cm2
9. Sub Pressure 350 Kg/cm2
10. Tension in Kg-F 250
CAUSES
1. FDP selection is not correct.
2. Due to the more stoppage of loom.
3. Setting of main nozzle is not correct.
4. Due to carelessness of weaver.
REMIDIES
1. Change the setting of FDP selection.
2. Reduce the RPM of loom.
3. Correct the Setting of main nozzle.
4. Train the weavers.
A PROJECT REPORT ON FABRIC DEFECTS 2010
49
STUDY OF ABRASION
LOOM PARTICULERS:-
Loom No. 663
Loom Type JAT 710 erotech
Loom rpm 880
Fabric Type Shirting
Warp Count 60sC
Weft Count 60sC
Ends / Inch 132
Picks / Inch 88
Reed Space 69 inch
Reed Used 132
Denting Order 2ends/dent
No. of Healds 4(Capacity 8)
Shedding Type Staubli cam shedding
Warp Tension 200 Kg-F
Shim Used 2mm
Weave PLAIN
LOOM STOP MARK SETTING:-
ICS SETTING:- S.NO. CHECK POINT SETTING
1. Warp × Weft 60×60
2. Beam Dia 390mm
3. Drawing width 175.2cm(act.169 cm)
4. Measuring Band mark 24
5. Number of sub nozzles 30
6. T0-Tw 90-240
7. WF1 Sensitivity 6
8. Main Pressure 300Kg/cm2
9. Sub Pressure 350 Kg/cm2
10. Tension in Kg-F 250
SAMPLE
A PROJECT REPORT ON FABRIC DEFECTS 2010
50
MECHANICAL SETTING:-
Back rest
Height & Depth
0 – 5
WSM Height -2
Easing Amount
& Timing
6 – 300o
Heald frame
Height &
Amount
S.No. Height Amount Dwell Cross 1. 76 138 0/60 310
o
2. 74 140 0/60 310o
3. 72 137 0/60 290o
4. 70 129 0/60 290o
CAUSES
1. Reed is tight and too hard.
2. Reed is defective.
3. Normal yarn is used in place of compact yarn.
REMIDIES
1. Re- tight the reed with torque wrench.
2. Change the defective reed.
3. Set early cross angle.
4. Increase the staggering.
5. Increase the shed angle.
NOTE:-
1. Abrasion due to the defective reed is sharp line.
2. Abrasion due to the hard tight reed is looks like wrong denting.
3. Abrasion due to the normal yarn is spresding and looks like pressure drop.
A PROJECT REPORT ON FABRIC DEFECTS 2010
51
STUDY OF OIL STAIN
LOOM PARTICULERS:-
Loom No. 613
Loom Type JAT 710 Eurotech
Loom rpm 800
Fabric Type Shirting
Warp Count 50s
Weft Count 50s
Ends / Inch 124
Picks / Inch 96
Reed Space 72
Reed Used 76/2
Denting Order 2 ends/dent
No. of Healds 10
Shedding Type Staubli Cam Shedding
Warp Tension 350 Kg-F
Shim Used 3mm
Weave PLAIN
CAUSES
1. Machine cleaning is not proper.
2. Oiling is not proper.
REMIDIES
1. Machine cleaning should be done weekly and monthly.
2. Oiling must be proper proper.
SAMPLE
A PROJECT REPORT ON FABRIC DEFECTS 2010
52
STUDY OF LOOSE FLUFF KNOT
1.
LOOM PARTICULERS:-
Loom No. 631
Loom Type JAT 710 Eurotech
Loom rpm 850
Fabric Type Shirting
Warp Count 40 MCL
Weft Count 60sC
Ends / Inch 72
Picks / Inch 86
Reed Space 72 inch
Reed Used 72/2
Denting Order 2 ends/dent
No. of Healds 4
Shedding Type Staubli Cam Shedding
Warp Tension 250Kg-F
Shim Used 2mm
Weave PLAIN
Loom No. 631
ICS SETTING:-
S.NO. CHECK POINT SETTING
1. Warp × Weft 40MCL×60
2. Beam Dia 536mm
3. Drawing width 163.1cm
4. Measuring Band mark 18
5. Number of sub nozzles 27
6. T0-Tw 90-240
7. WF1 Sensitivity 6
8. Main Pressure 350kPa
9. Sub Pressure 400kPa
10. Tension in Kg-F 240
SAMPLE
A PROJECT REPORT ON FABRIC DEFECTS 2010
53
2.
Loom No. 621
Loom Type TOYATA JAT 710
Loom rpm 805
Fabric Type Shirting
Warp Count
2/121s
Weft Count 60s
Ends / Inch 162
Picks / Inch 94
Reed Space 64.50
Reed Used 108/3
Denting Order 3 ends/dent
No. of Healds 4
Shedding Type Cam sedding
Warp Tension 240 Kg-F
Shim Used 2 mm
Weave Plain
SAMPLE
A PROJECT REPORT ON FABRIC DEFECTS 2010
54
ICS SETTING:-
S.NO. CHECK POINT SETTING
1. Warp × Weft 2/121×60
2. Beam Dia 536
3. Drawing width 1631
4. Measuring Bandmark 18
5. Number of sub nozzles 27
6. T0-Tw 90-240
7. WF1 Sensitivity 6
8. Main Pressure 350kPa
9. Sub Pressure 400kPa
10. Tension in Kg-F 240
CAUSES 1. It is weavers mistake.
2. Knotting is not proper.
REMIDIES Weaver should take care at the time of knotting.
A PROJECT REPORT ON FABRIC DEFECTS 2010
55
STUDY OF BOLLS FORMATION
LOOM PARTICULERS:-
Loom No. 623
Loom Type JAT 710
Loom rpm 800
Fabric Type Shirting
Warp Count 60s
Weft Count 60s
Ends / Inch 172
Picks / Inch 96
Reed Space 64.5 inch
Reed Used 171.8
Denting Order 3+4
No. of Healds 8(capacity 16)
Shedding Type E-Dobby Shedding
Warp Tension 220 Kg-F
Shim Used 4 mm
Weave Dobby
LOOM STOP MARK SETTING:-
ICS SETTING:- S.NO. CHECK POINT SETTING
1. Warp × Weft 60×60
2. Beam Dia 440mm
3. Drawing width 162.8cm(act. 160cm)
4. Measuring Band mark 16
5. Number of sub nozzles 28
6. T0-Tw 90-240
7. WF1 Sensitivity 6
8. Main Pressure 400kPa
9. Sub Pressure 450kPa
SAMPLE
A PROJECT REPORT ON FABRIC DEFECTS 2010
56
MECHANICAL SETTING:-
Back rest
Height &
Depth
0 – 6
WSM
Height
-1
Easing
Amount &
Timing
3 – 300o
Heald
frame
Height &
Amount
S.No.
Height
Dwell
Cross
angle
B.R*
Cross
angle
A.R.*
S. No.
Height
Dwell
Cross
angle
B.R*
Cross
angle
A.R.* 1. 104 0/30 300 330 5. 100 0/30 290 330 2. 102 0/30 300 330 6. 98 0/30 290 330 3. 100 0/30 300 330 7. 96 0/30 310 320 4. 98 0/30 300 330 8. 94 0/30 310 320
*B.R.=Before repairing; *A.R.=After repairing
CAUSES
1. Soft Beam
2. Normal Yarn
3. Small Shed Angle
4. Incorrect Frame Height
5. Incorrect WSM Setting
6. Delayed Cross Angle
REMIDIES
1. Highlight Soft Beam problem to your shift manager.
2. Increase the Shed Angle
3. Set bigger dwell.
4. Increase the tension.
5. Do correct setting of Frame Height
6. Do correct Setting of WSM
7. Set early Cross Angle
8. Reduce the RPM of loom.
A PROJECT REPORT ON FABRIC DEFECTS 2010
57
STUDY OF TIGHT WARP
Warp end or ends shifted to its right or left.
LOOM PARTICULERS:-
Loom No. 614
Loom Type JAT 710
Loom rpm 805
Fabric Type Shirting
Warp Count 102/2s
Weft Count 50s
Ends / Inch 108
Picks / Inch 92
Reed Space 66.0 inch
Reed Used 171.8
Denting Order 2 ends/dent
No. of Healds 8(capacity 16)
Shedding Type Dobby E-shedding
Warp Tension 240 Kg-F
Shim Used 4 mm
Weave Dobby
WSM Height -1
CAUSES 1. Cross Ends
2. Sticky Ends
3. Bolls Formation
4. Missing Ends from Beam
REMIDIES
1. Straighten the Cross Ends.
2. Set the WSM so as it should not touch the warp sheet.
3. Set the WSM so as it become parallel to warp sheet.
4. Train the Weaver to take regular patrolling of missing ends beam.
5. Reduce the RPM of Loom.
SAMPLE
A PROJECT REPORT ON FABRIC DEFECTS 2010
58
Ph(0) : 0512-2530199
: 05122-2531814
E-Mail : info@uptti.ac.in
Website : www.uptti.ac.in
UTTAR PRADESH TEXTILE TECHNOLOGY INSTITUTE
(Formerly Known as GCTI)
11/208, Souterganj, Parbati Bangla Road, Kanpur
________________________________________________________________________
____
To,
Mr. Subhanish Malhotra
Senior H.R.
Arvind mills Ltd.
Santej Ahmedabad.
Dear Sir,
This serves to acknowledge with thanks, the affection received by us from your
end. It gives us great pleasure to share with you that we have achieved our objective to get
the student acquainted with latest development in various technical and industrial fields .It
was possible due to the efforts of our team as well as the moral support from the people
from industry like you.
As the training has completed successfully we wish to request you to keep your
blessing on our efforts in future also.
Thanking You, Yours Truly,
Ajay Kumar
Deepak Rathour
Date- 26-07-2010 Deependra Kumar
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