Common Issues with Color-Woven Fabrics and Solutions

Common Issues with Color-Woven Fabrics and Solutions

Color-woven fabrics are a popular choice for their unique patterns and colors. However, they can sometimes be prone to certain issues that affect their quality and appearance. Here are some common problems and the ways to resolve them.

1. Weaving Defects

Color-woven fabrics may exhibit regular or irregular weaving defects along the warp or weft.

Causes:

• Insufficient yarn strength.
• Poor sizing of the yarn (light or heavy sizing).
• Faulty weaving machinery (malfunctions can lead to yarn breaks).
• Incomplete mending of the fabric after it comes off the loom.
• Careless final product inspection.

Solution: Strengthen the mending process.

2. Weft Skew/Weft Arc (Including Large and Small Grids)

For shuttle-woven and knitted fabrics, a weft skew/weft arc of 2% is acceptable, but any fabric with a skew greater than 3% is not considered first-grade.

Causes:

• Faulty weaving machinery (malfunctions can lead to frequent stops, causing weft skew/weft arc).
• Primarily caused by poor condition of the finishing equipment.
• Improper finishing (due to the carelessness of the operators).

Solution: Enhance mending and re-finishing (weft correction).

3. High Shrinkage Rate

If the shrinkage rate of the fabric in the warp and weft directions exceeds the specified values, it cannot be considered first-grade.

Causes:

• Poor finishing.
• Faulty pre-shrinking equipment.

Solution: Re-shrinking (to meet the specified shrinkage rate) or fabric shrinkage washing.

4. Inconsistent Hand Feel

The hand feel of the finished fabric is noticeably different from the sample.

Causes:

• Poor finishing.
• Incorrect raw materials.
• Incorrect production process.

Solution: Re-finishing or re-production.

5. Color Fastness Issues

The color fastness of the fabric (both color-woven and dyed fabrics) does not meet the requirements.

Causes:

• Poor dyeing process.
• Inferior dyeing materials.
• Poor finishing.
• Poor operation (especially noticeable in paint scraping/dyeing).

Solution: Re-fixing color, re-producing the fabric, re-dyeing (for dyed fabrics), or color repair (for paint scraping/dyeing fabrics).

6. Fabric Style Not Matching the Sample

There is a significant difference in the style of the fabric compared to the sample (bamboo joint style, segment dyeing style, thickness, etc.).

Causes:

• Incorrect raw materials (incorrect bamboo joint yarn/yarn count).
• Incorrect production process (incorrect segment dyeing process/incorrect arrangement of bamboo joint yarn or segment dyeing yarn).
• Incorrect finishing process (when the raw materials and weave are correct, the correctness of the finishing process affects the style of the fabric).

Solution: Adjust the raw materials, production process, and finishing process accordingly.