1. Seam Overprint
Symptom: Darker areas appear at both ends of the fabric.
Causes: Seam overprint is too wide or thick, tension is too high, the guide fabric is too short, or the color/texture of the guide fabric is inconsistent with the dyed material.
Solutions: Seam overprint should not be too wide; cut the seam to prevent water accumulation; adjust tension to a moderate level; use guide fabric similar in color to the dyed material.
2. Uneven Color at the Ends
Symptom: The color at both ends of the fabric is uneven.
Causes: Unclean guide fabric, dye not added according to performance, no cover applied, improper temperature control, or the guide fabric and dyed material are inconsistent.
Solutions: Keep the guide fabric clean; strictly follow dye characteristics when adding dye; cover and insulate during dyeing; use uniform materials.
3. Uneven Color at the Edge (Color Difference Between Edge and Center)
Symptom: The color of the fabric edge is inconsistent with the center.
Causes: Uneven roll width, lack of a cover, improper dye selection, excessive curvature of the dyeing frame, or temperature/pH difference between the edges and center.
Solutions: Ensure uniform roll width; use dyes with similar dyeing temperatures; control the curvature of the dyeing frame to 4-8mm (for silk); strengthen pretreatment to ensure consistent pH.
4. Wrinkles
Manifestation: Longitudinal wrinkles appear on the fabric surface.
Causes: Uneven seam ends, uneven fabric width, excessive steam impact, excessive tension, non-level dyeing frame, or yarn entanglement on the roller.
Solutions: Straighten seam ends; align the fabric width; control the boiling dyeing steam; adjust the tension appropriately; keep the dyeing frame level; clean the roller regularly.
5. Weft Skew
Manifestation: Skewed weft threads.
Causes: Uneven hand movements when entering the dyeing vat, excessive water pressure.
Solutions: Even hand movements when entering the dyeing vat; reduce the steam intensity during dyeing.
6. Pine-board Print
Appearance: Resembling tree rings.
Cause: Excessive tension or temperature during winding.
Solution: Reduce tension; pre-wind with cold water.
7. Color Variation
Appearance: Uneven color distribution on the fabric surface.
Cause: Insufficient water level; excessively rapid addition of dyeing accelerator; failure to cool down during material addition; excessively rapid temperature rise; insufficient sodium sulfide.
Solution: Ensure sufficient water level; add dyeing accelerator in batches; turn off steam and cool down before adding material; slowly increase temperature after 80℃; sodium sulfide concentration should not be less than 4g/L.
8. Color Stagnation
Appearance: Horizontal color stripes.
Cause: Mechanical malfunction causing shutdown.
Solution: Thoroughly check the equipment's operating status before restarting.
9. Color Difference (between rolls)
Appearance: Inconsistent color between different batches.
Causes: Fluctuations in process conditions, incomplete removal of floating dye from reactive dyes, and failure to strictly verify samples.
Solutions: Standardize process parameters; thoroughly wash to remove floating dye; strictly adhere to the sample verification procedure.
