I. Uneven Dyeing (Color Spots)
Immediate Action: Stop heating, check if the circulating pump pressure is stable, and confirm that the dye liquor flow rate is normal.
Treatment Method: If the nozzle is partially blocked, temporarily increase the pump speed for backflushing; if caused by excessively rapid heating, immediately reduce the heating rate to 1–1.5℃/cycle and extend the holding time to promote even dyeing.
II. Wrinkles and Claw Marks
Emergency Repair: Reheat the fabric to 2–5℃ higher than the original dyeing temperature, hold for 10–15 minutes, then slowly cool at a rate of ≤1℃/cycle to eliminate wrinkles using the thermal relaxation effect.
Prevention of Recurrence: Check if the fabric capacity is overloaded, adjust the nozzle pressure and guide roller tension to ensure smooth operation.
III. Excessive Foam
Quick Response: Avoid directly adding defoamers (which easily stain fabrics). Temporarily reduce the circulation speed to reduce turbulence, or add a small amount of low-foaming wetting agent to adjust.
Fundamental Solution: Replace with a low-foaming additive and use solvent scouring to remove oil stains from the fiber surface during the pretreatment stage.
IV. Nozzle Clogging or Fabric Blockage
Emergency Unblocking: Immediately activate the equipment's built-in backflushing unblocking device to clear the blockage using reverse pulse water flow.
Manual Intervention: If ineffective, stop the machine, disassemble the nozzle, and clean the channels with a soft brush; for knotted thin fabrics, gently untangle them manually to avoid forcibly pulling and causing fabric breakage.
V. Temperature Uncontrolled
On-site Handling: Check if the heat exchanger valves are responsive and confirm that the temperature control probe is not covered by dye liquor or scale. If the PLC displays abnormalities, switch to manual temperature control mode and operate according to the standard curve.
Calibration Recommendation: Verify sensor accuracy after production is completed and clean the heat exchange pipeline to prevent scale from affecting heat transfer.
VI. Poor Whiteness or Staining After Dyeing
Remedial Measures: For whitening varieties that exhibit a reddish or grayish sheen, a reduction cleaning can be performed: Use 5g/L sodium hydrosulfite + 1g/L caustic soda, treat at 85℃ for 20 minutes, rinse with water, and then re-match the color.
Long-Term Strategy: Before changing from dark to light, a high-temperature alkaline wash must be performed (130℃, 4–6kg caustic soda + 1–2kg detergent, 60–90 minutes) to thoroughly remove contaminants.
