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Knit Fabric Defects and Remedies
Knit Fabric Defects and Remedies
Knit Fabric Defects and Remedies
Faults or defects in knitting production can be caused in different ways and quite a few of them
cannot be related to just one cause. The following explanations are expected to be helpful in
trying to locate the causes of these faults easier.
Drop stitch
Possible causes:
a) In accurate insertion of the yarn into the needle hook;
Closed latch – a wale of dropped stitches will be produced until the latch is opened
either by the operator or due to machine vibration.
b) Broken needle hook;
c) Due to high yarn twist and low fabric take-down-tension the knitted loop could fall out of the
hook;
d) Improper setting of the yarn feed angle i.e. badly set yarn feeder
The yarn is not caught by the needle hook, Example-low yarn tension and high yarn
vibrations
e) Yarn feeder wrongly threaded-in;
f) Dial loop length not properly related to cylinder loop length; the loop jumps out of the needle
hook;
g) Bad take-up;
h) Very dry material;
i) Insufficient yarn tension.
Remedies:
Correct take-up of the fabric & correct fabric tension.
Ensure uniform yarn tension on all the feeders with a Tension Meter.
Rate of yarn feed should be strictly regulated as per the required Stitch Length.
Proper feeding of yarn during loop formation.
The fabric tube should be just like a fully inflated balloon, not too tight or too slack.
Needle should be straight & well.
The yarn being used should have no imperfections like; Slubs, Neps & big knots etc
The gap between the Cylinder & the Dial should be correctly adjusted as per the
knitted loop size.
Possible causes:
Individual yarns differ with respect to count, properties or structure;
Different course lengths in feeders.
B. Colour Barre'ness:
Possible causes:
Knitting of yarns which differ in colour;
Yarns dye differently during piece dyeing.
C. Shadow Barre'ness:
Possible causes:
Shadow like changes in the appearance of the fabric. Very difficult to detect and done by
reflected light.
Remedies:
Ensure uniform Yarn Tension on all the feeders.
Ensure that the hardness of, all the yarn packages, is uniform, using a hardness tester.
The average Count variation in the lot, should not be more than + 0.3
Ensure that the yarn being used for Knitting is of the same Lot / Merge no.
Bunching-up
Possible causes:
Specify the quality parameters of the yarns to be used for production to the yarn
supplier.
Preventing count or lot mixing.
Maintaining uniform yarn tension.
Fabric take-up should function properly.
8. Snagging:
Snags mainly occur while processing filament yarns. The tendency towards snagging can be
reduced by using yarns with a coarser single filament count, lesser crimp elasticity and higher
twist.
Snagging
Causes:
During knitting all mechanical influences, caused by rough surfaces on yarn guide elements,
yarn feeders, needles, fabric take-up, etc. have to be avoided. Even after knitting some snags can
appear especially during fabric setting, if its storage and further processing has not been
undertaken carefully.
Remedies:
Inspect & rectify the fabric contact points on all the machines (Soft Flow Dyeing, Tumble Dryer
& Centrifuge etc), on which snagging is taking place.
Using yarn with a coarser single filament count, lesser crimp elasticity and higher
twist.
During knitting on mechanical influences, caused by rough surfaces on yarn guide
elements, yarn feeders, needles, fabric take-up etc.