Knitted Fabric Defect

KNITTED FABRIC DEFECTS
-FIBRE/YARN
UNWANTED TUCK STITCH DUE TO
KITTIES
KITTIES
APPEARANCE
 MORE SPECKS ON THE FABRIC SURFACE
 HOLES IN THE FABRIC
 FABRIC SURFACE MORE HAIRY

KITTIES
CAUSES
 INEFFECTIVE OPENING AND CLEANING IN

BLOW ROOM AND CARDS
 USE OF HIGH TRASH PERCENTAGE

COTTON FIBRES
KITTIES
RECTIFICATION
 MORE OPENING TO BE GIVEN TO FIBRES IN

BLOW ROOM AND CARDS
 CLEANING EFFICIENCY MUST BE

IMPROVED.
 OPTIMUM SETTING OF MOTE KNIFES, C-

CLEANER, FLATS,ETC IN CARDING
NEPS
NEPS
APPEARANCE
 WHITE SPOTS ON THE FABRIC SURFACE
 STREAKY APPEARANCE
NEPS
CAUSES
 IMPROPER FIBER SELECTION
 POOR CARDING DUE TO IMPROPER

SETTING
 IMPROPER OPENING IN BLOW ROOM

NEPS
RECTIFICATION
 CORRECT SETTING AND SPEEDS IN BLOW

ROOM & CARD
 GRINDING SCHEDULES TO BE MAINTAINED

STRICTLY
 USE OF IMMATURE AND MORE SHORT

FIBRE COTTONS TO BE AVOIDED
HOLES DUE TO TRASH
HOLES DUE TO TRASH
APPEARANCE
 DAMAGED FABRIC
HOLES DUE TO TRASH
CAUSES
 HIGHER TRASH IN COTTON
 IMPROPER OPENING AND CLEANING IN

BLOW ROOM & IN CARD
HOLES DUE TO TRASH
RECTIFICATION
 SELECTION OF COTTON
 CLEANING EFFICIENCY OF BLOW ROOM &

CARD TO BE IMPROVED
POLYESTER
CONTAMINATION(SPIN)
POLYESTER CONTAMINATION
APPEARANCE
 WHITE LINE ON THE FABRIC
 STREAKY APPEARENCE
CAUSES
 IMPROPER OPENING AND CLEANING IN

BLOW ROOM
 FIBRE FLY IN SPINNING
 POOR HOUSEKEEPING
 IMPROPER HUMIDIFICATION
RECTIFICATION
 PROPER HOUSE KEEPING
 OPTIMUM HUMIDIFICATION
 PERFORMANCE OF OVERHEAD CLEANERS

TO BE MONITORED
 MACHINERY SURFACE TO BE CLEANED

LONG THIN PLACE IN YARN
LONG THIN PLACE
APPEARANCE
 THIN LINE APPEARANCE
 UNEVEN FABRIC SURFACE

LONG THIN PLACE
CAUSES
 MORE STRETCH IN SLIVER/ROVING
 MORE TENSION DRAFT APLLIED IN

DRAWING,SIMPLEX & RINGFRAME
 END BREAKS IN SLIVER DURING DRAWING

LONG THIN PLACE
RECTIFICATION
 MINIMISING TENSION DRAFT IN DRAW

FRAME, ROVING & RING FRAME
 MINIMISING STRETCH IN SLIVER & ROVING
 CLOSE DOWN THE SETTING FOR LONG

THIN FAULTS IN WINDING
LONG THICK PLACE
LONG THICK PLACE
APPEARANCE
 MORE UNEVEN SURFACE
 STREAKY/CLOUDY APPEARENCE
LONG THICK PLACE
CAUSES
 LASHING IN OF ROVINGS IN SIMPLEX
 BACK ROLLER LAPPING IN SPINNING
 MIX UP OF COARSER HANK

LONG THICK PLACE
RECTIFICATION
 OPTIMUM ROVING TWIST
 ROVING STOP MOTION TO BE CHECKED
 OPTIMUM HUMIDITY IN THE DEPARTMENTS

TO BE ENSURED
SHORT THIN PLACE
SHORT THIN PLACE
APPEARANCE
SHORT THIN PLACE
CAUSES
 ROLLER LAPPING IN RING FRAME
 HIGH YARN TENSION IN WINDING
 MORE HONEY DEW CONTENT
 DAMAGED TOP ROLLER COTS

SHORT THIN PLACE
RECTIFICATION
 OPTIMUM HUMIDITY IN THE DEPARTMENTS

TO BE ENSURED
 INCREASE THE ROLLER SCHEDULE FOR

COTS BUFFING
 CHECK SUGAR CONTENT IN COTTON

HOLES DUE TO LONG SLUB
APPEARANCE
 DAMAGED FABRIC
CAUSES
 POOR CARDING
 DEFECTIVE DRAFTING
 IMPROPERLY CLOTHED TOP ROLLER

CLEARERS
 IMPROPER TOP ROLLER PRESSURE
 ACCUMULATION OF FLY AND FLUFF

RECTIFICATION
 OPTIMUM TOP ROLLER PRESSURE
 PROPER FUNCTIONING OF ROLLER

CLEARERS/PNEMAFILSTO BE ENSURED
 MACHINE SURFACES TO BE CLEANED

YARN UNEVENNESS
YARN UNEVENNESS
APPEARANCE
 STREAKY/CLOUDY APPEARENCE
YARN UNEVENNESS
CAUSES
 ECCENTRIC TOP & BOTTOM ROLLERS
 WORN OUT/OLD APRONS
 INSUFFICIENT PRESSURE ON TOP

ROLLERS
 USE OF IMMATURE AND MORE SHORT

FIBRE CONTENT COTTON
YARN UNEVENNESS
RECTIFICATION
 AVOID ECCENTRICITY OF ROLLERS
 TOP ARM PRESSURE CHECKING TO BE

MAINTAINED STRICTLY
 OPTIMUM SPACER
 USE GOOD QUALITY COTTON

SNARLING IN YARN
SNARLING IN YARN
APPEARANCE
 DARK STREAKS
 HORIZONTAL DARK THICK LINE

SNARLING IN YARN
CAUSES
 HIGHER THAN NORMAL TWIST IN THE YARN
 PRESENCE OF TOO MANY LONG THIN

PLACES IN THE YARN
SNARLING IN YARN
RECTIFICATION
 OPTIMUM TWIST TO BE MAINTAINED FOR

THE TYPE OF COTTON USED
 MINIMISING THIN PLACES
 YARN TO BE CONDITIONED UNIFORMLY
 CORRECT TENSION WEIGHT AND SLUB

CATCHER SETTING TO BE EMPLOYED
HIGH TWIST YARN
HIGH TWIST YARN
APPEARANCE
 LIGHT COLOUR THIN LINE AT REGULAR

INTERVALS
HIGH TWIST YARN
CAUSES
 MIX UP OF YARNS BY THE

SUPPLIER/KNITTING OPERATOR
 WORN OUT RINGS/TRAVELLERS
 UNEVEN TENSION IN SPINDLE

TAPES,JOCKEY PULLEYS
HIGH TWIST YARN
RECTIFICATION
 PERIODIC REPLACEMENT OF WORN OUT

COTS,RINGS,TRAVELLERS,SPINDLE
TAPES,ETC
 PROPER MAINTENANCE AND LUBRICATION

OF JOCKEY PULLEYS
 OPTIMUM TENSION ON SPINDLE TAPES

BLEND VARIATION
BLEND VARIATION
APPEARANCE
 HORIZONTAL BANDS/LINES AT REGULAR

INTERVALS
BLEND VARIATION
CAUSES
 VARIATION IN HANK OF CARD / DRAWFRAME

SLIVER FROM SHIFT TO SHIFT
 IMPROPER COLOUR CODE IDENTIFICATION

MAINTAINED IN SPINNING
 MIX UP OF DIFFERENT YARNS BY SUPPLIER /

IN KNITTING
BLEND VARIATION
RECTIFICATION
 CONE LABELS TO BE CHECKED AT THE

TIME OF PACKING/CREELING
 COLOUR CODE IDENTIFICATION TO BE

FOLLOWED PROPERLY IN SPINNING
MIX UP OF YARNS HAVING DIFF
RKM VALUE
RKM VALUE
APPEARANCE
 WHITE LINES
 STREAKY LINES
RKM VALUE
CAUSES
 MIX UP OF COTTON HAVING DIFFERENT
PROPERTIES
 MIX UP OF YARNS BY THE
SUPPLIER/KNITTING OPERATOR
 WORN OUT RINGS/TRAVELLERS
 UNEVEN TENSION IN SPINDLE
TAPES,JOCKEY PULLEYS,ETC
RKM VALUE
RECTIFICATION
 PROPER MIXING PROCEDURE TO BE
FOLLOWED
 PERIODIC REPLACEMENT OF WORN OUT
COTS,RINGS,TRAVELLERS,SPINDLE
TAPES,ETC
 PROPER MAINTENANCE AND LUBRICATION
OF JOCKEY PULLEYS
 OPTIMUM TENSION ON SPINDLE TAPES
FOLLOWED STRICTLY
HORIZONTAL BANDS
LONG TAIL ENDS IN WINDING
APPEARANCE
 UNEVEN FABRIC SURFACE
CAUSES
 WRONG METHOD OF KNOTTING
 IMPROPER SETTING IN KNOTTING

MACHINE
RECTIFICATION
 TENTERS TO BE TRAINED IN PROPER

METHODS OF KNOTTING
 PROPER MAINTENANCE OF KNOTTING

MACHINE
CRAYON MARK
CRAYON MARK
APPEARANCE
 HORIZONTAL COLOUR LINE
 HORIZONTAL STREAKS
CRAYONMARK
CAUSES
 MARKING ON CONES USING PERMANENT

MARKERS
FILAMENTATION OF POLYESTER
YARN
FILAMENTATION
APPEARANCE
 FUZZY FABRIC APPEARANCE
 FABRIC SURFACE IS MORE HAIRY

FILAMENTATION
CAUSES
 WORN OUT YARN GUIDES IN YARN

WINDING / KNITTING STAGE.
 ABRASION OVER METAL PARTS.
 ROUGHNESS IN YARN PATH.
 IMPROPER SETTING OF YARN FEEDER

WITH RESPECT TO KNITTING NEEDLE.
FILAMENTATION
RECTIFICATION
 YARN WINDING DRUMS TO BE MAINTAINED
PROPERLY IN WINDING.
 WORN OUT YARN GUIDES TO BE
REPLACED IMMEDIATELY.
 YARN TRAVELLING PATH TO BE SMOOTH
AND MAINTAINED CLEAN
 SETTING BETWEEN FEEDER AND NEEDLE
SHOULD BE OPTIMUM.
MIX UP OF POLYESTER YARNS OF
TWO DENIERS
TWO DENIERS
APPEARANCE

INTERVALS
TWO DENIERS
CAUSES
 MIX UP OF DIFFERENT DENIER YARNS BY

SUPPLIER / IN KNITTING
TWO DENIERS
RECTIFICATION


FOLLOWED STRICTLY
VARIATION IN NO OF FILAMENTS
APPEARANCE

INTERVALS
CAUSES
 MIX UP OF DIFFERENT DENIER YARNS BY

RECTIFICATION


FOLLOWED STRICTLY
MIX UP OF YARNS HAVING
DIFFERENT MERGE NOS
DIFFERENT MERGE NOS
APPEARANCE

INTERVALS
DIFFERENT MERGE NOS
CAUSES

 MIX UP OF DIFFERENT YARNS BY

DIFFERENT MERGE NOS
RECTIFICATION


FOLLOWED STRICTLY
MIX UP OF SINGLE AND DOUBLED
YARN
YARN
APPEARANCE
 HORIZONTAL BANDS AT REGULAR

INTERVALS
YARN
CAUSES

 MIX UP OF DIFFERENT YARNS BY

YARN
RECTIFICATION


FOLLOWED PROPERLY IN SPINNING
UNEVEN GASSING OF YARN
APPEARANCE
 UNEVEN SHADE
CAUSES
 DIFFERENCE IN TEMPERATURE,
FREQUENCY & SPEED OF GASSING
MACHINE
RECTIFICATION
 UNIFORM SETTING TO BE SET

KNITTED FABRIC DEFECTS
-KNITTING
CONTAMINATION(KNITTING)
 GENERALLY CONTAMINANT TWISTED WITH NORMAL

YARNS OCCURS DURING SPINNING STAGE (MOSTLY
OF HAIR, JUTE, POLYOLEFINIC TYPE OF FIBRES,
ETC)
 FOREIGN FIBRES LOOSELY ADHERED ON THE

NORMAL YARN OCCURS DURING KNITTING .
APPEARANCE
 COLOURED SPOTS ON THE FABRIC SURFACE
 POOR FABRIC APPEARENCE

CAUSES
 Storage of yarn in open atmosphere.

 Poor house keeping.
 Improper humidification (dry condition causes more
fibre flys)
 Accumulation of fibre flys from adjacent machines. (Dyed
or grey fibres)
 Poor cleaning of knitting elements, guides, etc
 Poor cleaning practices.
 Uncovered knitting machines.
Remedies :
 Store knitting yarns at proper temperature and humidity in

sealed containers.
 Use adequately spaced aisles.
 Reseal used yarn containers.
 Maintain 55-65% RH, 25 +/- 2 Deg C in knitting .
 Post cleaning guide lines of floors and knitting elements.
 Knitting elements to be cleaned with compressed air at
every fabric doff.
 Each and every machines to be covered by polyethylene
sheets.
Remedies :
 Performance of humidification plants to be monitored.

 Maintain proper house keeping.
 Cleaning of knitting machine beds, positive storage
feeder drive points then and there when fly’s/fluffs are
observed.
 Proper cleaning of aluminum/PVC yarn guide tubes once
in a day.
TUCK OR MISS STITCH DEFECT DUE
TO FLUFF(KNITTING)
TUCK OR MISS STITCH DEFECT
DUE TO FLUFF(KNITTING)
APPEARANCE
 DROP OR TUCK STITCHES

 APPEARS LIKE HOLES
 CHANGE OF DESIGN PATTERN
Causes :
 High yarn input tension.

 High knitting speed.
 Increased tightness factor .
 Rough yarn paths.
 Storage of grey yarn in open air.
 Poor house keeping.
 Improper humidification (dry condition cause more fibre
flys)
 Accumulation of fibre flys from adjacent machines.
Causes :
 Incorrect or close needle gaiting increases fly and fluffs.

 Wear and tear in needles .
 Poor cleaning of knitting machine.
 Poor cleaning practices.
 Uncovered knitting machines.
 Improper yarn carrier setting.
Remedies :
 Procure less hairy yarn.

 Maintain optimum and uniform input yarn tension. (3 – 8
gms for cotton yarn)
 Replace rough yarn guides.
 Proper maintenance of yarn path.
 Maintaining optimum take down tension.
 Damaged needles should be replaced.
 Needle gaiting should be widened.
 Set the yarn carrier , in such a way so that it directly feed
into the hook of the needles
Remedies :
 Cleaning the knitting machine twice in a month.

 Place water tub below the creel zone to reduce fibre fly.
 Hard waste and volume fluffs must be collected in waste
pockets.
 Store knitting yarns at proper temperature and humidity
in sealed containers
 Use adequately spaced aisles.
 Reseal used yarn containers.
Remedies :
 Maintain 55-65% RH, 25 +/- 2 Deg C in knitting zone.

 Knitting elements to be cleaned with compressed air at
every fabric doff.
 Each and every machines to be covered by polyethylene
sheets.
 Performance of humidification plants to be monitored.
 Maintain proper house keeping.
 Cleaning of knitting machine beds, positive storage feeder
drive points then and there when fly’s/fluffs were observed.
 Proper cleaning of aluminum/PVC yarn guide tube once in
a day.
PIECING DEFECT IN KNITTING
APPEARANCE
 DIRTY FABRIC APPEARANCE
 UNEVEN FABRIC APPEARENCE

Causes :
 Improper work practices.

 Lack of operator training.
 Careless material handling / oiling.
 Mending of yarn breaks with oily / soiled hands.
 Piecing with long tail ends or extra ends.
 Long piecing length.
 Piecing along with Loose ends.
Remedies :
 Knitting operators to be trained in piecing practices.

 Appropriate material handling procedures.
 Use of French chalk powder during piecing.
 Piecing of yarns, after removing the defective part of yarn
like slubs/ fluffs,etc
 Loose yarns to be collected in waste bags.
NEEDLE LINES
NEEDLE LINES
 APPEARANCE
 VERTICAL DARK/LIGHT - BAND/LINE
 VERTICAL STREAKS
NEEDLE LINES
Causes :
 Processing of poor quality yarn having more slubs, thick ,
knots & lumps deteriorates the life and quality of needles.
 Frequent hitting of the said yarn faults to the needles,
bent the needles or break the needle parts.
 Poor quality needles
 Improper setting of yarn carrier to the needles.
 High yarn tension.
 Gaiting off
 Dirty or bent needle slots.
 Loose or worn cams.
 Cylinder eccentricity
 Improper take down tension.
NEEDLE LINES
Causes :
 Insufficient lubrication to the needles.

 Poor quality lubrication oil.
 High lint deposition on cam and cylinder tricks.
 Worn out latches.
 Stiff latches.
 Worn out or damaged needle butts.
 Cylinder or dial play.
 Higher machine speed
 Bent or damaged cylinder tricks.
NEEDLE LINES
Remedies :
 Use good quality yarn.
 Needle latches should not be over oiled, they might
become clogged and sticky.
 Needles should be checked weekly for wear, especially
while running coarser or harsh yarns.
 Use good quality lubricating oil.
 Proper lubricating procedures and schedules to be
followed.
 Cleaning of fluffs or lint deposition of cylinder tricks and
cam tricks once in a week.
 Cleaning of knitting elements and knitting area.
 Using soft bristle brushes to close the latches.
NEEDLE LINES
Remedies :
 Keeping Cylinder or dial eccentricity below 0.03 mm
 Tightening loose cams and changing worn out cams.
 Uniform yarn input and fabric out put tension.
 Optimum setting between yarn carrier and needles.
 Poor cleaning practices.
 Needle life depends upon machine speed, tightness of the
fabric, yarn quality, lubrication, type of yarn, etc. As per the
case studies conducted, the life of the good needle knitting
cotton single jersey fabric will be 75000 – 1 lakh Kgs.
NEEDLE LINES
Remedies :
 If the deviation of working length of needle exceeds the

value of 0.02mm needle line will appear.
 If the deviation of needle from left/right or right / left exceeds
the value of 0.01mm needle line will appear.
 Needle breakage rate below 0.5 per 100 Kg (good) for S/J.
SINKER LINE
SINKER LINE
APPEARANCE
 VERTICAL DARK/LIGHT - BAND/LINE
 VERTICAL STREAKS
SINKER LINE
Causes :
 Processing of poor quality yarn having more slubs, thick ,

knots & lumps deteriorates the life and quality of sinkers.
 Improper setting of sinkers and yarn carrier guide
 High yarn tension.
 Bent or damaged sinker slots.
 Loosen sinker cam
 Damages in sinker cams.
 Wear and tear in sinker nose
 Wear and tear in loop holding part
SINKER LINE
Causes :
 Accumulation of fluffs between the sinkers

 Accumulation of fluffs in sinker slots.
 Sticky sinkers
 Over oiled sinkers
 Sinker play
 Difference sinking depth (ribbed appearance)
SINKER LINE
Remedies :
 Use of good quality yarns.

 Use of good quality sinkers.
 Optimum clearance between sinker and yarn carrier guide
should be below - 03”
 Uniform and less input yarn tension.
 Proper cleaning of machine.
 Sinker timing to be even.
 Replacing damaged cams and sinkers, etc.
 Proper lubrication
 Using same quality sinker sets.
 Correcting damaged sinker slots.
OIL LINE
OIL LINE
APPEARANCE
 Vertical dark/light - band/line
 Vertical streaks
 Horizontal lines/bands effect with oil stains.
 Oil with stains.

OIL LINE
Causes :
 More oil lubrication used in knitting machine.

 Malfunction in oil let off system.
 Poor quality oil
 Clogging of oil lubricator points.
 Damaged oil tubes
 More fluffs in the cylinder tricks or cam tracks, (which
have burnt during needle movement, appears like black
burn fibre)
OIL LINE
Causes :
 Oil with burnt fibres causes stained oil line.

 Less amount of oil also causes high friction and burns the
clogged fibres.
 Improper cleaning / oiling of knitting machine.
 Sometimes over oiling may cause oil leakage from
cylinder and bed gap.
 Water content in the oil. (moisture from the compressed
air)
OIL LINE
Remedies :
 Oil flow setting to be optimum .

 Replace damaged oil tubes
 Optimum oil pressure to be maintained at different oiling
points.
 Clean cylinder tricks and cam tracks twice in a month, if
you knit harsh yarns or dyed yarns.
 Oil flow tubes should be checked daily for any damages or
clogging of fluffs, etc
 While oiling manually , don’t oil in same position or feeder.
 Use quality oil or oil recommended by machine
manufacturer.
 Optimum knitting machine speed to be maintained.
 Check the compressed air daily.
COURSE LENGTH VARIATION
APPEARANCE
 STREAKY FABRIC APPEARANCE
 UNEVEN FABRIC SURFACE
 HORIZONTAL DARK/LIGHT LINES AT REGULAR

INTERVALS
Causes :
 Variation in yarn package density.
 Yarn tension variation between the feeders.
 Slippage in positive feeder.
 Wrong yarn path.
 Improper setting of positive feeder.
 Positive feeder cap not locked properly.
 Difference in length of yarn wound on positive storage
feeder.
 Fluffs in yarn carrier guides, tensioners, slub catchers,
feed tubes,etc.
 Worn out guides.
 Improper setting of yarn carriers.
 Improper setting of needle and sinker cams.
Remedies :
 Clean the knitting elements, guides and feed tubes with

compressed air once in a day.
 Clean the positive feeder drive bearing.
 Keep uniform tension in all the feeders.
 Correct the slippage of positive feeders.
 Instruct the operators to lock the positive feeder cap.
 Change the yarn package having high/low package
densities.
Remedies :
 Change the worm out guides.

 Check the yarn path.
 Proper setting of positive feeders, needle cams, sinker
cams and yarn carriers.
 Proper cleaning of machines and floors.
 Course length variation should be below +/- 1%
UNEVEN FABRIC SURFACE DUE TO
DIFFERENCE IN YARN TENSION
Appearance :
 Streaky lines on the fabric for shorter lengths.

Causes :
 Belt slippage : Positive feeder drive, belt tension not set

properly.
 Fluffs adhered on positive feeder pins or teeth.
 Belt of positive storage feeder is not in contact with the
pins or toothed wheels properly.
 Fluff accumulation on yarn guides, positive storage
feeders, feed tubes, etc
 Rough yarn path.
 Fabric take down too weak.
 Improper yarn tensioner setting or worn out tensioner
springs in positive feeders.
Remedies:
 Adjust the belt tension of positive storage feeder.

 Clean the pins/tooth of the positive storage feeder.
 Clean the drive belt with light rag.
 Change the damaged belt, yarn guides ,etc
 Clean the yarn guides.
DEFECTS DUE TO POSITIVE
FEEDER DRIVE BELT SLIPPAGE
Appearance :
 Intermittent streaks on all feeders in the given fabric,

which appears like diagonal lines with streaks effect.
Causes :
 Clogging of fluffs in Quality adjustment pulley.

 Damaged Q A Pulley.
 Improper belt tension.
 Damaged belt
 Slippage in belt tensioning device.
 Damaged belt tensioning device.
Remedies :
 Clean QAP and belt regularly.

 Replace the damaged parts in QAP.
 Change the damaged belt.
 Belt should be set, so that the tape applies equal
pressure on all contact wheels.
 Belt should run along top or bottom of the all wheels.
 The belt should touch only the pins or teeth on contact
wheels and not the housing of the wheel.
 Rough edges of the belt should be trimmed.
 Belt should contact at same point on all wheels.
DEFECTS DUE TO SINKER SETTING
DEFECT NORMAL
APPEARANCE
 WHITE SPOTS ON THE FABRIC SURFACE
 BACK LOOP APPEARS AT FACE SIDE OF THE

FABRIC
CAUSES :
 Improper setting of sinker cam

 Damages in sinkers
 Uneven loop yarn or binding yarn tension
 Variation in sinker timing.
 Improper yarn carrier setting
Remedies :
 Set all the sinker timing even.

 Adjust the sinker backwards to decrease the length of
sinker loop.
 Change the damaged sinkers
 Keep uniform yarn tension in fleece and binding loop.
 In case of cotton and polyester yarn blended fabric,
mostly polyester filament yarn will be used as binding
thread. In such cases, After the approval of lab dyed
sample, proceed for bulk knitting production. Grey fabric
sample from all the knitting machines (different diameter)
should be send for lab dyeing.
DIAGONAL BANDS
DIAGONAL BANDS
APPEARANCE
 DIAGONAL BANDS AT REGULAR INTERVAL

DIAGONAL BANDS
Causes :
 Eccentricity of QAP.
 Clogging of fluffs in Quality adjustment pulley.
 Damaged Q A Pulley.
 Improper belt tension.
 Damaged belt
 Slippage in belt tensioning device.
 Damaged belt tensioning device.
DIAGONAL BANDS
Remedies:
 Correct the eccentricity of QAP.
 Clean QAP and belt regularly.
 Clean the wastes at the contact points of belt and QAP
regularly.
 Replace the damaged parts in QAP.
 Change the damaged belt.
 Belt should be set, so that the tape applies equal pressure
on all contact wheels.
 Belt should run along top or bottom of the all wheels.
 The belt should touch only the pins or teeth on contact
wheels and not the housing of the wheel.
 Rough edges of the belt should be trimmed.
 Belt should contact at same point on all wheels.
LYCRA CUT
LYCRA CUT
APPEARANCE
 FABRICS SURFACE HAS MORE UPS AND DOWNS
 DAMAGED FABRIC APPEARANCE
 PROTRUDING OF CUT LYCRA ON THE FABRIC

SURFACE
LYCRA CUT
Causes :
 Wrong lycra yarn path.

 Accumulation of fluff in lycra feeders, guides , etc.
 Tension difference in lycra yarns.
 Sticky lycra yarn package.
 Difference in package diameter and density
 Worn out guides or guide rollers.
 High machine speed.
 High take down tension / pressure
 Improper working of lycra feeders.
 Belt slippage in lycra feeders.
 Worn out or rough paths in drive rollers of lycra feeders.
LYCRA CUT
Causes :
 Worn out needles or sinkers.

 Improper timing of needles and sinkers.
 Cylinder eccentricity
 Improper setting of lycra driven feeders.
 Improper gaiting.
LYCRA CUT
Remedies :
 Smooth lycra yarn paths.

 Replacement of worn out guides and rollers.
 Smooth running of lycra guide rollers.
 Optimum take down tension / pressure
 Correcting the belt slippage.
 Lycra package diameter should be even for all feeders.
 Optimum machine speed.
 Correct setting of lycra guide rollers to yarn carrier
guides.
LYCRA CUT
Remedies :
 Replacing damaged needles / sinkers.

 Lycra packages should not be kept long time in open air.
 Proper timing of sinkers and needles.
 Correcting the eccentricity of cylinder.
 Providing smooth drive to lycra package.
LYCRA TENSION VARIATION
A : WAVY EFFECT : DEFECT

B: NORMAL
APPEARANCE
 WAVY APPEARANCE
 HORIZONTAL BAND/LINE AT REGULAR INTERVALS

Causes :
 Wrong lycra yarn path.

 Accumulation of fluff in lycra feeders, guides , etc.
 Tension difference in lycra yarns.
 Sticky lycra yarn package.
 Difference in package diameter and density
 Worn out guides or guide rollers
 Improper working of lycra feeders.
 Belt slippage in lycra feeders.
Causes :
 Worn out or rough paths in drive rollers of lycra feeders.

 Over stretch or less stretch of lycra yarn.
 Improper timing of needles and sinkers.
 Cylinder / dial eccentricity
 Improper setting of lycra driven feeders.
 Gaiting off
Remedies:
 Smooth lycra yarn paths.

 Replacement of worn out guides and rollers.
 Smooth running of lycra guide rollers.
 Correcting the belt slippage.
 Lycra package diameter should be even for all feeders.
 Optimum machine speed.
 Correct setting of lycra guide rollers to yarn carrier guides.
 Replacing damaged needles / sinkers.
Remedies:
 Lycra packages should not be kept long time in open air.

 Proper timing of sinkers and needles.
 Correcting the eccentricity of cylinder.
 Providing smooth drive to lycra package.
 Use same quality lycra yarns.
HORIZONTAL BANDS
HORIZONTAL BANDS
 Causes :
 Lack of operator training in terms of knowledge about
fibres and yarns.
 Cylinder eccentricity.
 Excessive lint deposition inside the cam tracks or cylinder
tricks.
 Difference in Setting between sinker cam ring and sinker.
 Improper yarn tension at feed.
 Wrong selection of yarn feed drive mechanism (While
using two tier)
 Jerky take up
 Improper material handling and storing
 Worn out yarn guides.
HORIZONTAL BANDS
Remedies :
 Training of operatives.
 If the barre defect is being seen in the grey sample,
interchange the cones in the feeder and visualize the
effect of barre
 Lab dip dyeing of nearest shade of customer can be
done to visualize the effect of barre after dyeing.
 Interchange the cones to other knitting machine, to
analyse whether the barre is due to knitting machine.
 Check the mill name, lot number, date of purchase, cone
identification, labels before creeling the cones in the
knitting machine
 Rewinding of cones
HORIZONTAL BANDS
Remedies :
 Check the cones if you suspect shade difference

between the cones under U.V lamp.
 Cylinder or dial eccentricity should below 0.03 mm.
 Check the eccentricity of cylinder every month.
 Clean the cam tracks and cylinder tricks twice in a
month.
 Height of dial should be uniform.
 Minimise machine vibration.
 Sinker to sinker cam setting to be uniform.
 Eccentricity of sinker ring below 2/1000”
 Optimum and uniform input yarn tension.
HORIZONTAL BANDS
Remedies :
 Proper maintenance of knitting machine.

 Replace worn out ceramic guides.
 Stitch cams to keep the ratio of dial stitch to cylinder
stitch the same at all the dial and cylinder feeds.
 Take down tension of fabric must be uniform through out
the fabric width.
HOLES
HOLES
Causes :
 Bad needles
 Take down mechanism too tight
 Gaiting off causes needles to rub
 Needles too tight in their slots
 Dial height too low or high.
 Needle timing set wrong.
 Improper stitch setting.
 Yarn carriers set wrong.
 Damages in sinkers.
 Uneven yarn tension.
 Due to fly’s or fluffs
HOLES
Remedies :
 Change the worn out needles or sinkers

 Set cylinder gaiting correctly
 Uniform and optimum take down tension.
 Uniform and optimum yarn tension.
 Optimum fabric texture.
 Cleaning of knitting elements, cylinder tricks and guides
regularly.
 Even timing for all needles.
 Yarn carrier to needle setting should be optimum for
closing and opening of latches. (Clearance between
needle and yarn carrier)
 Proper cleaning of knitting machine elements and floors to
avoid flys or fluff generation.
DEFECTS DUE TO TAKEN DOWN
MECHANISM : LOOP LOADING
MECHANISM : SNAGGING
MECHANISM : HOLES
MECHANISM : EDGE CREASE MARK
MECHANISM : CREASE MARKS
MECHANISM :
Defects Causes Remedies
Crease marks High take down roller Reduce the take down
(Edges of the pressure. roller pressure.
fabric) (Side Rough spreader edges or Smoothen the nylon
crease marks)* nylon rollers in spreader. rollers.
Improper setting of Height of the spreader
spreader. from take down rollers to
be uniform
MECHANISM :
Snagging Rough or sharp edges in Replace or correct the
(pulling of yarn spreader or taken down damaged rollers and
or loops rollers. spreaders
vertically)* Loosen fasteners which
might have abraded with Tight the fasteners.
fabric
MECHANISM :
Holes* Rough or sharp edges in Replace or correct the
spreader or taken down damaged rollers and
rollers. spreaders
Loosen fasteners which
might have abraded with Tight the fasteners.
fabric
MECHANISM :
Bands Jerky take down , wear and Replace with new ones.
tear in gears or chains,etc.
Crease marks Low take down tension. Optimum take down
(Irregular Improper setting of tension.
crease marks) spreader from take down Height of the spreader
rollers. from take down rollers to
Low spreader width. be uniform
Spreader width to be
adjusted to optimum level
to stretch the fabric width.

Knitted Fabric Defect

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KNITTED FABRIC DEFECTS

 MORE SPECKS ON THE FABRIC SURFACE

 HOLES IN THE FABRIC

 FABRIC SURFACE MORE HAIRY

 INEFFECTIVE OPENING AND CLEANING IN

 USE OF HIGH TRASH PERCENTAGE

 MORE OPENING TO BE GIVEN TO FIBRES IN

 CLEANING EFFICIENCY MUST BE

 OPTIMUM SETTING OF MOTE KNIFES, C-

 WHITE SPOTS ON THE FABRIC SURFACE

 IMPROPER FIBER SELECTION

 POOR CARDING DUE TO IMPROPER

 IMPROPER OPENING IN BLOW ROOM

 CORRECT SETTING AND SPEEDS IN BLOW

 GRINDING SCHEDULES TO BE MAINTAINED

 USE OF IMMATURE AND MORE SHORT

 HIGHER TRASH IN COTTON

 IMPROPER OPENING AND CLEANING IN

 CLEANING EFFICIENCY OF BLOW ROOM &

 WHITE LINE ON THE FABRIC

 IMPROPER OPENING AND CLEANING IN

 FIBRE FLY IN SPINNING

 PROPER HOUSE KEEPING

 PERFORMANCE OF OVERHEAD CLEANERS

 MACHINERY SURFACE TO BE CLEANED

 THIN LINE APPEARANCE

 UNEVEN FABRIC SURFACE

 MORE STRETCH IN SLIVER/ROVING

 MORE TENSION DRAFT APLLIED IN

 END BREAKS IN SLIVER DURING DRAWING

 MINIMISING TENSION DRAFT IN DRAW

 MINIMISING STRETCH IN SLIVER & ROVING

 CLOSE DOWN THE SETTING FOR LONG

 MORE UNEVEN SURFACE

 LASHING IN OF ROVINGS IN SIMPLEX

 BACK ROLLER LAPPING IN SPINNING

 MIX UP OF COARSER HANK

 OPTIMUM ROVING TWIST

 ROVING STOP MOTION TO BE CHECKED

 OPTIMUM HUMIDITY IN THE DEPARTMENTS

 MORE UNEVEN SURFACE

 ROLLER LAPPING IN RING FRAME

 HIGH YARN TENSION IN WINDING

 MORE HONEY DEW CONTENT

 DAMAGED TOP ROLLER COTS

 OPTIMUM HUMIDITY IN THE DEPARTMENTS

 INCREASE THE ROLLER SCHEDULE FOR

 CHECK SUGAR CONTENT IN COTTON

 IMPROPERLY CLOTHED TOP ROLLER

 IMPROPER TOP ROLLER PRESSURE

 ACCUMULATION OF FLY AND FLUFF

 OPTIMUM TOP ROLLER PRESSURE

 PROPER FUNCTIONING OF ROLLER

 MACHINE SURFACES TO BE CLEANED

 MORE UNEVEN SURFACE

 ECCENTRIC TOP & BOTTOM ROLLERS

 WORN OUT/OLD APRONS

 INSUFFICIENT PRESSURE ON TOP

 USE OF IMMATURE AND MORE SHORT

 TOP ARM PRESSURE CHECKING TO BE