Common Defects in Knitted Fabrics with Causes and Remedies

Common Defects in Knitted Fabrics with Causes and Remedies

Shubham Yadav
B.Sc. in Textile Engineering
Government Central Textile Institute,
Kanpur, Uttar Pradesh

Faults in Knitted Fabrics:

Knitted fabrics are widely used in the textile and apparel industry due to their flexibility, softness, and comfort. However, during the knitting process, various defects can occur, affecting the appearance, quality, and performance of the fabric. The imperfections of knitted fabric may be due to faulty yarns, malfunctioning knitting machine parts or poor finishing. The defects in knitting construction are considered here in terms of appearance and nature.

A defect of the knitted fabric is an abnormality which spoils the aesthetics i.e. the clean and uniform appearance of the fabric and effects the performance parameters, like; dimensional stability etc.

There are various types of defects which occur in the Knitted fabrics of all types caused by a variety of reasons. The same type of defects may occur in the fabric due to a variety of different causes e.g. Drop Stitches, Spirality etc. Understanding these common defects, their causes, and remedies is essential for maintaining high-quality knitted fabrics.

Category of Knitted Fabric Defects:

Yarn Related Defects:

Almost all the defects appearing in the horizontal direction in the knitted fabric are yarn related. These defects are mainly;

1. Barriness
2. Thick and Thin lines
3. Dark or Light horizontal lines (due to the difference in dye pick up)
4. Imperfections
5. Contaminations
6. Snarling
7. Spirality

Knitting Elements Related Defects:

Almost all the defects appearing in the vertical direction in the knitted fabrics are as a cause of bad Knitting Elements. These defects are mainly;

1. Needle and Sinker Lines
2. Drop Stitches etc.

Machine Settings Related Defects:

These defects appear randomly in the knitted fabrics due to the wrong knitting machine settings and that of the machine parts. The defects are mainly;

1. Drop Stitches
2. Yarn Streaks
3. Barriness
4. Fabric press off
5. Broken Ends
6. Spirality

Dyeing Related Defects:

The Dyeing related defects are as follows;

1. Dyeing patches
2. Softener Marks
3. Shade variation
4. Tonal variation
5. Color fading (Poor Color Fastness)
6. Dull shade
7. Crease or rope Marks

Finishing Related Defects:

Defects caused mainly due to the wrong process parameters are;

1. High Shrinkage
2. Skewing
3. Spirality
4. Surface Hairiness and Pilling
5. Tonal variation
6. Snagging (Sharp points in the dyeing machine or trolley etc)
7. Fold Marks
8. Wet Squeezer Marks
9. GSM variation
10. Fabric Width variation
11. Curling of S.J. Fabrics

Without above these defects, The major defects in knitted fabric can be divided into (1) bands and streaks and (2) stitch defects.

Bands and streaks:

• Barré effect
• Skewing
• Bowing
• Streak or stop mark
• Needle line

Stitch defects:

• Dropped stitch
• Cloth press off
• Cockled or puckered
• Crack or hole
• Tucking (bird’s eye)
• Float

1. Drop Stitches (Holes)

Definition:
Drop Stitches are randomly appearing small or big holes of the same or different size which appear as defects in the Knitted fabrics. This is a lost stitch caused either by the yarn carrier not having been set properly or the stitch having been knitted too loosely. This may be attributed to improper setting of the yarn feeder or insufficient yarn tension. To solve the dropped stitch problem, re-adjust the yarn feeder or increase the yarn tension.

Major Causes:

• High Yarn Tension
• Yarn Overfeed or Underfeed
• High Fabric Take Down Tension
• Defects like Slubs, Neps, Knots etc.
• Incorrect gap between the Dial and Cylinder rings.

Remedies:

• Ensure uniform yarn tension on all the feeders with a Tension Meter.
• Rate of yarn feed should be strictly regulated as per the required Stitch Length.
• The fabric tube should be just like a fully inflated balloon, not too tight or too slack.
• The yarn being used should have no imperfections like; Slubs, Neps and big knots etc
• The gap between the Cylinder and the Dial should be correctly adjusted as per the knitted loop size.

2. Barriness

Definition:
Barre or Barriness defect appears in the Knitted fabric in the form of horizontal stripes of uniform or variable width. A barré effect has the appearance of a stripe with shaded edges. It is a continuous visual barred or striped pattern parallel to the yarn direction. Barré is caused by inconsistencies in fibre properties, yarn characteristics, knitting parameters and processing. In order to prevent barré effect on knitted fabric, it is necessary to maintain consistency throughout each phase of textile production

Causes:

• High Yarn Tension
• Count Variation
• Mixing of the yarn lots
• Package hardness variation

Remedies:

• Ensure uniform Yarn Tension on all the feeders.
• The average Count variation in the lot should not be more than + 0.3
• Ensure that the yarn being used for Knitting is of the same Lot .
• Ensure that the hardness of all the yarn packages is uniform using a hardness tester.

3. Skewing

Skew can be defined as a fabric condition occurring when the knitted wales and courses are angularly displaced from the ideal perpendicular angle. The skewing effect is seen as a line or design running at a slight angle across the cloth. It is an inherent defect mainly caused by yarn twist parameters. Firstly, the high yarn twist levels result in yarns that exhibit high inherent torsion energy as a result of their great tendency to untwist. The yarn exhibits significant snarling effect, high liveliness and consequently, poor fabric dimensional stability. Second, the effect of fabric skewness is caused by yarn twist direction. Yarn twist direction depends on the direction of machine rotation. For machines rotating in a counterclockwise direction, yarns made using Z twist direction yielded fabric of lower spirality than those made using S direction. Air jet spun yarn made using S twist direction yielded higher fabric spirality than that made on Z direction. In principle, the skew caused by one set of yarn is countered by that of the other set. The effect of twist direction can also be compensated for by yarns that are doubled or plied for knitting. Doubled yarns are expected to yield lower fabric spirality than single yarns. Below figure illustrates a comparison between a normal fabric and a skewed fabric in both wale and course direction.

Causes:

• Improper yarn tension during knitting
• Imbalanced twist in the yarn
• Incorrect take-down or cam settings

Remedies:

• Use yarns with balanced or lower twist
• Maintain consistent yarn tension throughout knitting
• Adjust take-down and cam settings properly

4. Streakiness

Definition:
Streaks in the Knitted fabrics appear as; irregularly spaced and sized, thin horizontal lines. A straight horizontal streak or stop mark in the knitted fabric is due to a difference in tension in the yarns, caused by the machine being stopped and then restarted.

Causes:

• Faulty winding of the yarn packages.
• Yarn running out of the belt on the Pulley

Remedies:

• Winding of the yarn package should be proper.
• The yarn should be running between the belt and around the pulley.

5. Imperfections

Definition:
Imperfections appear on the fabric surface in the form of unevenly placed or randomly appearing Knots, Slubs and Neps, Thick and Thin places in the yarn.

Causes:

• Big Knots, Slubs and Neps in the yarn, Thick and Thin yarn.

Remedies:

• Specify the quality parameters of the yarns to be used for production to the yarn supplier.

6. Snarls

Definition:
Snarls appear on the fabric surface in the form of big loops of yarn getting twisted due to the high twist in the yarn.

Causes:

• High twist in the yarn.

Remedies:

• Twist in the yarn should be in required TPM.

7. Contaminations

Definition:
Contaminations appear in the form of foreign matter such as; dyed fibers, husk, dead fibers etc. in the staple spun yarn or embedded in the knitted fabric structure.

Causes:

• Presence of dead fibers and other foreign materials, such as; dyed fibers, husk and synthetic fibers etc.
• Dyed and other types of fibers flying from the adjacent Knitting machines cling to the yarn being used for knitting and get embedded in the Grey Fabric.

Remedies:

• Use rich fiber mixing for the yarns to be used for Knitting in order to have less dead fibers appearing in the fabric.
• Rigid control measures in the Blow Room to prevent the mixing of foreign matters in the Cotton mixing.
• Segregate the Spinning and Knitting Machines, with Plastic Curtains or Mosquito Nets, to prevent the fibers flying from the neighboring machines, from getting embedded in the yarn / fabric.

8. Spirality

Definition:
Spirality appears in the form of a twisted garment after washing.The seams on both the sides of the garment displace from their position and appear on the front and back of the garment.

Causes:

• High T.P.I. of the Hosiery Yarn
• Uneven Fabric tension on the Knitting machine.
• Unequal rate of Fabric feed on the Stenter, Calender and Compactor machines.

Remedies:

• Use the Hosiery yarns of the recommended TPM level for Knitting.
• Ensure uniform rate of feed of the dyed fabric on both the edges while feeding the fabric to the Calender, Compactor or Stenter machines.

9. Needle Lines

Definition:
Needle line is a vertical creak that is different from the adjacent normal wales. This is caused by needle movement due to a tight fit in its slot or a defective sinker. It can also be caused by a misaligned or broken needle, which will produce distorted stitches.

Causes:

• Bent Latches, Needle Hooks and Needle stems
• Wrong Needle selection (Wrong sequence of needles, put in the Cylinder or Dial)

Remedies:

• Inspect the grey fabric on the knitting machine for any Needle lines.
• Check the Needle filling sequence in the Cylinder / Dial grooves (tricks).

10. Horizontal lines

Definition:
Horizontal lines in knitted fabric are unwanted visible streaks or bands running across the width of the fabric (weft direction). These lines can be faint or distinct and often result in an uneven appearance, affecting fabric quality and aesthetics.

Causes:

• Fault in bobbin
• Irregular tension on cams.

Remedies:

• Replace that bobbin.
• Check cams positioning

11. Broken Needles / Laddering

Definition:
Defects caused by the broken needles show prominently as vertical lines parallel to the Wales. There are no loops formed in the Wale which has a broken needle.

Causes:

• High Yarn Tension
• Bad Setting of the Yarn Feeders
• Old and Worn out Needle set
• Cylinder Grooves are too tight restricting needle movement
• Breakage of hook or butt in needle.

Remedies:

• Ensure uniform and the right Yarn tension on all the feeders.
• Keep the recommended gap between the Yarn Feeders and the Needles.
• Periodically change the complete set of needles.
• Remove fly or blockage from groove.
• Replace defective needle.

12. Cockled or puckered

Definition:
The knitted fabric appears wavy when spread flat. This is difficult to detect during visual inspection on an inspection machine with fabric under roller tension. It is usually due to uneven stitches, stitch distortion, uneven yarn relaxation or shrinkage.

Causes:

• Differential shrinkage of yarns or fibers
• Improper fabric relaxation or heat setting
• Inconsistent stitch length or loop formation

Remedies:

• Use yarns with similar shrinkage properties
• Ensure proper fabric relaxation and heat setting
• Maintain uniform stitch length and machine adjustments

13. Sinker Lines

Definitions:
Sinker lines are prominent or feeble vertical lines appearing parallel to the Wales along the length of the knitted fabric tube.

Causes:

• Bent or Worn out Sinkers
• Sinkers being tight in the Sinker Ring grooves

Remedies:

• Replace all the worn out or bent sinkers causing Sinker lines in the fabric.
• Sinker lines are very fine and feeble vertical lines appearing in the fabric.
• Remove the fibers clogging the Sinker tricks.

14. Oil Lines

Definitions:
Oil lines are prominent vertical lines which appear along the length of the knitted fabric tube. The lines become permanent if the needle oil used is not washable and gets baked due to the heat during the finishing of the fabric.

Causes:

• Fibers and fluff accumulated in the needle tricks which remain soaked with oil.
• Excessive oiling of the needle beds.

Remedies:

• Fibers accumulated in the needle tricks cause the oil to seep into the Fabric.
• Some lubricating oils are not washable and can not be removed during Scouring.
• Remove all the Needles and the Sinkers of the machine periodically.
• Clean the grooves of the Cylinder and Dial of the machine thoroughly with petrol.
• Blow the grooves of the Cylinder Dial and Sinker ring with dry air after cleaning.

15. Broken Ends

Definition:
Broken ends appear as equidistant prominent horizontal lines along the width of the fabric tube when a yarn breaks or is exhausted.

Causes:

• High Yarn Tension
• Yarn exhausted on the Cones.

Remedies:

• Ensure correct yarn tension on all the feeders.
• Ensure that the Yarn detectors on all the feeders are working properly.
• Depute a skilled and alert machine operator on the knitting machine.

16. Fabric Press Off

Definition:
Fabric press off appears as a big or small hole in the fabric caused due to the interruption of the loop forming process as a result of the yarn breakage or closed needle hooks.

Press off takes place, when the yarn feeding to both the short butt and long butt needles suddenly stops due to the yarn breakage. At times complete fabric tube can fall off the needles if the needle detectors are not functioning or are not properly set.

This defect results from broken yarn coming away from the knitting needles during knitting. A serious press off can be a big section or the entire tube of circular knitted fabric coming off the knitting needles. Press off often occurs accidentally with yarn breakage(s). One preventive measure that can be taken in order to eliminate or reduce the defect is to maintain a smooth yarn path from the cone to the knitting needles. In double jersey knitting, the problem or the extent of the defect can be reduced with alternate needles at alternate feeds.

Causes:

• End breakage on feeders with all needles knitting.
• Yarn feeder remaining in lifted up position due to which the yarn doesn’t get fed in the hooks of the needles.

Remedies:

• Needle detectors, should be set precisely to detect the closed needles and prevent the fabric tube from completely pressing off.
• Proper yarn tension should be maintained on all the feeders.

17. Float

Definition:
A float is defined as a length of yarn extending unbound over a number of wales with which it should be intermeshed. This is caused by a missed stitch, which can be due either to the failure of one or more needles to rise to catch the yarn, or to the yarn prematurely casting off from the knitting elements.

Causes of Knitted Fabric Float Defects:

• Inconsistent or slack yarn tension causing yarn to miss knitting.
• Damaged, bent, or improperly timed needles failing to catch yarn.
• Incorrect machine settings such as wrong stitch length or yarn feeder alignment.

Remedies for Knitted Fabric Float Defects:

• Maintain and adjust uniform yarn tension throughout knitting.
• Inspect and replace faulty or bent needles regularly.
• Properly set and calibrate machine parameters including stitch length and yarn feeder position.

18. Surface Hairiness and Piling

Definition:
Surface hairiness appears in the form of excess superfluous fibers, on the surface of the knitted fabrics, which have either been reprocessed, or tumble dried.

Pilling appears as, small fiber balls formed on the fabric surface, due to the entanglement of loose surface fibers. Factors such as, the fiber staple length, low T.P.M. and fabric construction (with long yarn floats) etc. also contribute to pilling.

Causes:

• Abrasion due to the contact with rough surfaces
• Excessive surface hairiness caused, due to the abrasive tumbling action
• Fabric friction in the Tumble Dryer
• Rough Dyeing process and abrasive machine surfaces (Soft Flow Machine tubes, Tumble Dryer drum etc.)
• Reprocessing of the fabric is, also a major cause of piling.

Remedies:

• Avoid using the Tumble Dryer.
• Control shrinkage by maximum fabric relaxation and over feed in the processing.
• Regularly inspect the fabric contact points on all the machines, for any rough and sharp surface.
• Avoid repeated reprocessing of the fabrics.
• Use anti pilling chemical treatments for the fabrics prone to pilling.

19. Snagging

Definition:
Snagging appears on the knitted fabric surface as a pulled up yarn float showing up in the form of a large loop.

Causes:

• Caused by the pulling or the plucking of yarn from the, fabric surface, by sharp objects.

Remedies:

• Inspect and rectify the fabric contact points on all the machines (Soft Flow Dyeing, Tumble Dryer and Centrifuge etc), on which snagging is taking place.

20. Bowing

Definition:
Bowing appears as rows of courses or yarn dyed stripes forming a bow shape along the fabric width. A bow effect is observed when the course line form an arc across the width of knitted fabric. It is defined as an excessive curvature of the courses in a knitted fabric that may or may not extend over the full width. Bowing is the distortion caused by a faulty take-up mechanism on the knitting machine. It can also be caused by incorrect feeding during the finishing process.

Causes:

• Uneven distribution of tensions across the fabric width while dyeing or finishing the fabric.

Remedies:

• Bowing can be corrected by reprocessing the fabric by feeding it from the opposite end.
• A special machine (MAHLO) is also available for correcting the bowing in the knitted fabrics.

21. Dyeing Patches

Definition:
Dyeing patches appear, as random irregular patches on the surface of dyed fabrics.

Causes:

• Inadequate Scouring of the grey fabric is one of the primary causes of the dyeing patches.
• Improper leveling agent is also one of the causes of dyeing patches.
• Correct pH value not maintained.
• Dyeing machine stoppage due to power failure or the fabric entanglement in the dyeing machine are a major cause of the dyeing patches.

Remedies:

• Scour the grey fabric thoroughly to remove all the impurities from the fabric before dyeing.
• Use appropriate leveling agents to prevent patchy dyeing.
• Maintain the correct pH value during the course of dyeing.
• Use a power back up (Inverter) for the dyeing operation to be completed uninterrupted.

22. Softener Marks

Definition:
Softener marks appear as distinct irregular patches in the dried fabric after the application of softener.

Causes:

• Softener not being uniformly dissolved in water

Remedies:

• Scour the grey fabric thoroughly to remove all the impurities from the fabric before dyeing.
• Ensure that the softener is uniformly dissolved in the water and doesn’t remain un-dissolved as lumps or suspension.
• Use the right softener and the correct procedure for the application.
• Maintain the correct pH value of the softener before application.

23. Stains

Definition:
Stains appear as spots or patches of grease oil or dyes of different color, in a neat and clean finished fabric surface.

Causes:

• Dyeing Machine not cleaned thoroughly after dyeing a lot.
• Grease and Oil stains from the unguarded moving machine parts like; Gears Shafts Driving Pulleys and Trolley wheels etc.
• Fabric touching the floors and other soiled places during transportation, in the trolleys.
• Handling of the fabric with soiled hands and stepping onto the stored fabric with dirty feet or shoes on.

Remedies:

• Wash and clean the dyeing machine thoroughly after dyeing every dye lot.
• Follow the dyeing cycle of Light- Medium- Dark shades and then the reverse the cycle while dyeing the fabric.
• All the lubricated moving machine parts should be protected with safety guards.
• Make sure that the fabric is neatly packed in or covered with Polythene sheets while transporting or in storage.
• Handle the fabric carefully with clean hands and do not let anyone step onto the stored fabric.

24. Color Fading (Poor Color Fastness)

Definition:
The color of the garment or the fabric appears lighter and pale in comparison to the original color of the product after a few uses.

Causes:

• Dyeing recipe i.e. the poor fixing of the dyes is a major cause of color fading.
• Using the wrong combination of colors in a secondary or tertiary shade.
• Use of strong detergents and the quality of water are also the common causes for color fading.
• Prolonged exposure to strong light will also cause the colors to fade.
• High level of acidity or alkalinity in the perspiration of individuals also causes color fading.

Remedies:

• Use the correct dyeing recipe i.e. the appropriate leveling, fixing agents and the correct combination of dyes.
• Follow the wash care instructions rigidly.
• Use mild detergents and soft water for washing the garments.
• Don’t soak the garments for more than 10- 15 minutes in the detergent prior to washing
• Turn the wet garments inside out while drying.
• Dry in shade and not in direct sunlight.
• Protect the garments against prolonged direct exposure to strong lights (show rooms or exhibitions etc.).

25. Shade Variation (Roll to roll and within the same roll)

Definition:
Sometimes there appears to be a difference in the depth of shade between the roll to roll and from place to place in the same roll. The defect will show up clearly in the garments manufactured from such fabric.

Causes:

• Shade variation can be as a result of mixing of the, fabrics of two different lots.
• Shade variation is also caused, by the variation in the process parameters i.e. Time, Temperature and Speed etc. from one fabric roll, to the other.
• Shade variation can appear to be, in fabrics with GSM variation, caused due to the uneven stretching, unequal fabric overfeed % etc.

Remedies:

• Ensure that the grey fabric used for one shade is knitted from the same lot of the yarn.
• Ensure that the same process parameters (Width, Overfeed, Temperature and Machine Speed etc.) are used for each roll of a dye lot.

26. Tonal Variation

Definition:
Roll to roll or within the same roll difference in the color perception i.e. Greenish, Bluish, Reddish or Yellowish etc. is attributed as tonal variation in the shade.

Causes:

• Wrong Dyeing recipe
• Wrong leveling agent selection or wrong dyes combinations.
• Improper fabric Scouring.
• Impurities like Oil and Wax etc. not being completely removed in Scouring
• Level dyeing not being done due to the inappropriate leveling agents.
• Variation in the process parameters, e.g. Temperature, Time and Speed etc .

Remedies:

• Use appropriate leveling agents to ensure uniform and level dyeing.
• Scour the grey fabric thoroughly to ensure the removal of all the impurities.
• Ensure that the whole lot of the dyed fabric is processed under uniform process parameters.

27. Wet Squeezer Marks

Definition:
The fabric on the edges of the fabric tube gets permanent pressure marks due to the hard pressing by the squeezer rolls. These marks appear as distinct lines along the length of the fabric and can’t be corrected.

Causes:

• These marks are caused due to the excessive pressure, of the squeezer rolls of the Padding Mangle, on the wet fabric, while rinsing.

Remedies:

• Use the Padding mangle only for the application of the softener.
• Use a hydro extractor (Centrifuge) for the extraction to avoid the squeezer roll marks.
• Soon after extraction open the fabric manually to prevent crease marks in the damp fabric.

28. Folding Marks

Definition:
Fold marks appear as distinct pressure marks along the length of the fabric.

Causes:

• 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 Calander and Compactor is the primary cause of the folding marks in the knitted fabric.

Remedies:

• Adjust the gap between the two rolls as per the thickness of the fabric sheet .
• Gap between the two Calander 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 and structured fabrics.

29. Crease Marks

Definition:
Crease marks appear in the knitted fabric, as dark haphazard broken or continuous lines.

Causes:

• Damp fabric moving at high speed in twisted form, in the Hydro extractor (Centrifuge).

Remedies:

• Use anti Crease, during the Scouring and the Dyeing process .
• The use of anti Crease, swells the Cellulose and prevents the formation of Crease mark.
• Spread the fabric in loose and open form and not in the rope form, in the Hydro Extractor.

30. High Shrinkage

Definition:
The original intended measurements of the Garment go, haywire, during storage or after the very first wash.

Causes:

• High Stresses and strains exerted on the fabric, during Knitting, Dyeing and Processing and the fabric not being allowed to relax properly, thereafter.
• High shrinkage is primarily due to the fabric being subject to high tension, during the Knitting, Dyeing and the Finishing processes

Remedies:

• Keep the Grey Fabric in loose plated form, immediately after the roll is cut.
• Store the finished fabric also in the plated form and not in the roll form.
• Allow the fabric to relax properly, before it is cut.
• Give maximum overfeed to the fabric, during the processing, on the Stenter, Compactor and the Calandering machines.

31. Tucking (bird’s eye)

Definition:

This appears as a small aperture occurring occasionally in a wale. It is generally caused by unintentional tucking from a malfunctioning needle, with two small, distorted stitches, side by side. Another reason is incorrect dial settings. If the dial is set too high, the dial needles do not support the fabric, which then pulls the fabric up. Tucking is also caused by incorrect feeding during finishing.

Causes:

• Malfunctioning or damaged needle causing unintentional tucking
• Tension variation or insufficient/incorrect yarn feed during knitting
• Incorrect machine settings, such as improper fabric take-up or wrong course density

Remedies:

• Replace or repair faulty needles and ensure proper needle maintenance
• Adjust and maintain uniform yarn tension and ensure correct yarn feeding
• Set correct fabric take-up and course density according to specifications

32. GSM Variation

Definition:
The fabric will appear to have a visible variation in the density, from roll to roll or within the same roll of, the same dye lot.

Causes:

• Roll to roll variation in the, process parameters, of the fabric, like; Overfeed and Width wise stretching of the dyed fabric, on the Stenter, Calender and Compactor machines.
• Roll to roll variation in the fabric stitch length.

Remedies:

• Make sure that all the fabric rolls in a lot, are processed under the same process parameters.
• The Knitting Machine settings, like; the Quality Pulley diameter etc. should never be disturbed.

33. Fabric Width Variation

Definition:
Different rolls of the same fabric lot, having difference in the finished width of the fabric.

Causes:

• Grey fabric of the same lot, knitted on different makes of Knitting Machines, having varying number of Needles in the Cylinder.
• Roll to roll difference, in the Dyed Fabric stretched width, while feeding the fabric on the Stenter, Calander and Compactor.

Remedies:

• The whole lot of the grey fabric should be knitted on the same make of knitting machines.
• For the same gauge and diameter of the knitting machines, there can be a difference of as high as 40 needles, from one makes to the other make of the machine.
• This difference, in the number of needles, causes a difference of upto 2”-3” in the finished width of the fabric
• The stretched width of the grey fabric should remain constant, during finishing on the stenter.

34. Measurement Problems

Definition:
The measurements of the garments totally change after, a few hours of relaxation and after the first wash. The arm lengths or the front and back lengths of the garments may vary, due to the mix up of the parts.

Causes:

• Shrinkage caused due to the inadequate relaxation of the knitted fabrics, before cutting.
• Mixing of the garment parts cut from, different layers or different rolls of the knitted fabric.

Remedies:

• Use a trolley, for laying the fabric on the table, to facilitate a tension free, laying.
• Let the fabric relax for a few hours, before cutting, especially the Lycra fabrics.
• Ensure the numbering of the different layers of the fabric, to prevent the mix up of the components.

Conclusion

Defects in knitted fabrics can severely impact the final quality and performance of garments. Regular monitoring of yarn quality, machine maintenance, and operator training can significantly reduce these issues. By identifying the root causes and implementing effective remedies, manufacturers can produce higher-quality knitted fabrics while minimizing waste and rework.

Mazharul Islam Kiron

Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. Mr. Kiron is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.

Share this Article!