I. Improper Operation
Adding material before the fabric has run smoothly: Adding material before the machine has run smoothly for 3-5 minutes causes the fabric to not fully expand and become knotted.
Neglecting inspection: Operators fail to observe the fabric's running status in real time, missing early signs of clogging (such as sluggish operation or pressure fluctuations), delaying the opportunity to address the problem.
II. Fabric Characteristics and Dye Solution Issues
Lightweight, high-density fabrics are prone to floating: Fabrics such as spring spun yarn and polyester taffeta are high-density and lightweight, and after entering the machine, they do not sink in the dye solution but float on the surface, easily tangling and knotting.
Excessive foam in the dye bath causing "air swells": The use of foaming auxiliaries or high water hardness leads to a large amount of foam in the dye solution, forming "air swells" that hinder fabric flow and induce clogging.
III. Inadequate Process Design
Failure to Use Full Overflow: The "full overflow" process was not used for easily floating fabrics, failing to guarantee complete fabric immersion and stable circulation.
Lack of Degassing Measures: Degassing agents were not added to the dye bath, making it difficult for air carried by the fabric fibers to escape, causing localized floating and sluggish operation.
IV. Inadequate Equipment Maintenance
Filter Clogging:Filters were not cleaned according to specifications (once per shift for medium-length fibers, once daily for filaments), leading to impurity accumulation, increased circulation resistance, and fabric clogging.
Nose and Return Valve Not Adjusted in Time: When changing processing types, the nozzle diameter and return valve opening were not adjusted simultaneously, resulting in an imbalance in the fabric-to-liquid ratio and a turbulent flow field.
