I. Nozzles: Prone to "Air Bubbling" and Clogging
Symptoms: Fabric movement is sluggish, resulting in knots or "chicken claw" wrinkles.
Causes: Impurities in the dye liquor deposit and fiber debris accumulate, causing partial blockage of the nozzles; improper internal flow field design of the nozzles leads to gas accumulation and "air bubbling."
Prevention: Regularly disassemble and clean the nozzles, optimize the structure, and install flow control plates to regulate the flow field and eliminate spiral flow.
II. Circulation Pump (Main Pump): Insufficient Power or Overheating
Symptoms: Slower dye liquor flow rate and fluctuating circulation pressure lead to uneven color distribution.
Causes: Insufficient bearing lubrication, impeller corrosion, or motor aging; frequency converter control system parameter drift.
Solutions: Regularly lubricate the shaft seat, check motor insulation and voltage stability, and calibrate the frequency converter settings.
III. Heat Exchanger: Uncontrolled Heating/Cooling
Symptoms: Large temperature fluctuations, failure of precise temperature control within ±0.5℃, affecting dye uptake.
Causes: Scale buildup on heat exchange tubes reduces heat transfer efficiency; slow valve response or sensor malfunction.
Maintenance Recommendations: Perform chemical cleaning every 3 months to remove scale; calibrate the temperature control probe to ensure the gradient temperature control system operates normally.
IV. Guide Rollers: Wear and Abrasion on Fabric
Symptoms: Pilling, fuzzing, or misalignment of the fabric surface.
Causes: Long-term friction causes scratches on the roller surface; uneven tension in passive guide rollers.
Improvement Directions: Use actively driven guide rollers to reduce sliding friction; regularly check roller concentricity and surface smoothness.
V. Filter: Frequent Clogging
Symptoms: Increased resistance to dye liquor circulation, increased pressure before the pump.
Causes: Failure to clean the filter screen in a timely manner, especially when processing high-hair yarns or recycled fibers, which are more prone to clogging.
Operating Procedures: Medium-length fiber fabrics should be brushed once per shift, while polyester filament fabrics should be cleaned daily.
VI. Fabric Storage Tanks and Dye Vats: Accumulated Stains and Residual Dye Contamination
Symptoms: Poor whiteness and severe staining when converting from dark to light colors.
Cause Analysis: Incomplete cleaning of the dye vat after dyeing, leaving residual dye adhering to the vat walls.
Resolution: Before converting from dark to light colors, a high-temperature alkaline wash (130℃, caustic soda + detergent) for 60–90 minutes is necessary to thoroughly drain the contaminants.
