Yarn faults and

package defects
causes, effects and
remedies
INTRODUCTION

During processing, textile materials are subjected to various stresses not

only during the machine operation but also during its stoppage. If these stresses
exceeded a given limits it will adversely affect the quality of the produced
yarns, fabrics and the efficiency of the machines .

In weaving process, the strains on warp ends can lead to thread breaks, loss of
quality and shutdowns. Warp breaks still represent major problem especially for
today's high-speed weaving machines.

From the thorough investigation it is seen that the following faults are yarn faults,
yarn package faults, and mechanical faults in spinning.
 Discussion
time

 Lets discuss about the yarn

faults and package defects
occurring in your spinning
department…
 YARN FAULTS
1 SLUB
2 NEPS PACKAGE
3 SNARL
DEFECTS
4 THICK AND THIN PLACES
5 SOFT YARN 1 STITCHING ON CONE
6 OILY STAINED YARN
2 RIBBON WOUND CONE
7 BAD PIECING
8 OILY SLUB 3 SOFT BUILD CONES
9 KITTY YARN 4 BELL SHAPED CONE
10 HAIRINESS 5 NOSE BULGINGG
11 FOREIGN MATTERS 6 COLLAPSED CONE
12 SPUN IN FLY
CORK SCREW YARN 7 RING SHAPED CONE
13
1 SLUBS YARN FAULTS

 An abnormally thick place or lump in yarn showing less twist at that

place.
CAUSES
1. Accumulation of fly and fluff on the machine parts.
2. Poor carding.
3. Defective rotor drafting and bad piecing

EFFECT
1. More end breaks in warping process.
2. Damaged fabric appearance.
3. Shade variation in dyed fabrics.

REMEDIES
1. Machine surfaces to be maintained clean.
2. Proper functioning of pnemafil/roller cleaners has to be ensured
3. Broken teeth gear wheel to be avoided and proper meshing has to be ensured.
4. Better fiber individualization at cards to be achieved.
5. Optimum top roller pressure &back zone
6. Setting at ring and rotor has to be maintained.
2 NEPS YARN FAULTS

 Yarn containing rolled fiber mass, which can be clearly seen on black board at
close distance; measurable on USTER imperfection Indicator.
 CAUSES
1. Accumulation of fly and fluff on the machine parts
2. Poor carding (Insufficient stripping and Dirty under casing (grid bar), High roller speed ,
Uneven flats setting)
3. Defective rotor and bad piecing of robot
4. Improper clothed top roller cleaner

EFFECT
1. Damaged fabric appearance
2. Shade variation in the dyed fabrics
3. An abnormally thick place or lump in yarn showing less twist at that place is called slubs

REMEDIEs
1. Machine surfaces has to be maintained clean.
2. Damaged rotor has to be avoided and proper maintained.
3. Proper functioning of pnemafil/roller cleaners has to be ensured
4. Broken teeth gear wheel to be avoided and proper meshing has to be ensured.
5. Better fiber individualization at cards to be achieved.
3 SNARL YARN FAULTS

 Yarn with kinks (twisted onto itself) due to insufficient tension after twisting
3 SNARL YARN FAULTS

CAUSES
1. Higher than normal twist in the yarn
2. Presence of too many long thin places in the yarn

EFFECT
1. Entanglement with adjacent ends causing a break
2. Damaged fabric appearance
3. Improper meshing of gears
4. Shade variation in dyed fabrics
5. Mixing of cottons varying widely in fiber lengths and use of immature cottons

REMEDIES
1. Optimum twist to be used for the type of cotton processed
2. Drafting parameters to minimize thin places in the yarn to be adopted
3. Yarn has to be conditioned
4. Correct tension weights and slub catcher settings to be employed at winding
4 THICK AND THIN PLACES YARN FAULTS

Measurable by USTER Imperfection Indicator and observable on appearance

4 THICK AND THIN PLACES YARN FAULTS

CAUSES
1. Non-uniform sliver
2. Problem in mixing
3. Defect rotor surface
4. Eccentric top and bottom rollers
5. Insufficient pressure on top rollers
6. Worn and old aprons and improper apron spacing
7. Improper meshing of gear wheels
8. Mixing of cottons varying widely in fiber lengths and use of immature cottons

EFFECT
1. Damaged fabric appearance
2. Shade variation in dyed fabrics
3. Mixing of cottons varying widely in fiber lengths and use of immature cottons
4. More breakage in warping

REMEDIES
1. Defective rotor to be avoided
2. Right the card setting and top & bottom rollers setting
3. Top arm pressure checking schedules to be Maintained strictly
4. Wide variation in the properties of cottons used in the mixing to be avoided
5. Better fiber individualization at cards to be achieved.
6. Correct spacers has to be utilized
5 SOFT YARN YARN FAULTS

Yarn which is weak indicating lesser twist

5 SOFT YARN YARN FAULTS

CAUSES
1. Improper feed in rotor and Improper bobbin feed on the spls
2. Slack tapes dirty jockey pulleys
3. Less twist in the yarn
4. Bad rotor and Bad clearing at the traveler

EFFECT
1. More end breaks in subsequent processes such as warping, winding etc.
2. Shade variation in dyed fabrics

REMEDIES
1. Proper yarn clearing to be ensured
2. Vibration of bobbins on the spindles to be avoided
3. Periodic replacement of rotor to be effected
4. Periodic replacement of worn rings and travelers to be effected
6 OIL STAINED YARN YARN FAULTS

Yarn stained with oil

6 OIL STAINED YARN YARN FAULTS

CAUSES
1. Careless oil in the moving parts, over head pulleys etc
2. Piecing made with oily or dirty fingers
3. Careless material handlings

EFFECT
1. Damaged fabric appearance
2. Occurrence of black spot in fabric

REMEDIES
1. Appropriate material handling procedures to be followed
2. Oilers to trained in proper method of lubrication
3. Clean containers to be utilized for material transportation
 BAD PIECING YARN FAULTS

Unduly thick piecing in yarn caused by over End piecing

CAUSES
1. Wrong method of piecing and over end piecing
2. Twisting the ends instead of knotting

EFFECT
1. More end breaks in subsequent process
2. Increase in hard waste

REMEDIES
1. Operators has to be trained in proper methods of piecing
2. Separators to be provided
3. Excessive end breaks in spinning has to be avoided
 OILY SLUB YARN FAULTS

Slub in the yarn stained with oil

EFFECT
1. More end breaks in the warping process
2. Damaged fabric appearance
3. Shade variation in dyed fabrics

CAUSES
1. Accumulation of oily fluff on machinery parts
2. Poor methods of lubrication in preparatory processes
3. Negligence in segregating the oily waste from process waste

REMEDIES
1. Yarn contact surfaces to be kept clean
2. Proper segregation of oily waste from process waste
3. Oilers to be trained in correct procedures of lubrication
 KITTY YARN YARN FAULTS

Presence of black specks of broken seeds, leaf bits and trash in yarn

CAUSES
1. ineffective cleaning in Blow room and cards
2. Use of cottons with high trash and too many seed coat
fragments

EFFECT
1. Damaged fabric appearance
2. Production of specks during dyeing
3. Needle breaks during knitting
4. Poor performance during winding

REMEDIES
1. Cleaning efficiency of blow room and cards to be improved
2. Optimum humidity in the departments to be ensured
HAIRINESS YARN FAULTS

Protrusion of fiber ends from the main yarn structure

 HAIRINESS YARN FAULTS

CAUSES
1. Use of cottons differing widely in the properties in the same mixing
2. Use of worn rings and lighter travelers
3. Improper mixing
4. Maintaining low relative humidity, closer roller settings and very high spindle speeds

EFFECT
1. More breaks in winding and warping
2. Formation of holes and stains in cloth
3. Uneven fabric surface
4. Beads formation in the fabric in the case of polyester/cotton blends

REMEDIES
1. Proper mixing or blending
2. Use of travelers of correct size and shape and rings in good condition to be ensured
3. Periodic maintenance of different parts
4. Roller settings to be maintained
5. Optimum relative humidity to be maintained in the spinning room
6. Wide variation in the properties of cottons used in the mixing to be avoided
 FOREIGN MATTERS YARN FAULTS

Metallic parts, jute flannel and other similar foreign matters spun along with yarn

CAUSES
1. Improper preparation of mixings
2. Improper setting of foreign material separator in blow room.
3. Improper handling of travelers

EFFECT
1. Breaks during winding and warping
2. Formation of holes and stains in cloth
3. Damaged fabric appearance

REMEDIES
1. Improper setting of cleaning zone.
2. Removal of foreign matters(such as jute fibers, color cloth bits)
to be ensured during preparation of mixing
3. Installation of permanent magnets at proper
4. Places in blow room lines to be ensured
 SPAN FLY YARN FAULTS

Fly fluff either spun along with the yarn or loosely embedded on the yarn

CAUSES
1. Accumulation of fluff over machine parts
2. Fanning by workers
3. Failure of over head cleaners
4. Malfunctioning of humidification plant

EFFECT
1. More breaks in winding and warping

REMEDIES
1. Machinery surfaces to be kept clean by using roller pickers
2. Fanning by workers to be avoided
3. Performance of over head cleaners and humidification plants to be closely monitored
 CORK SCREW YARN

It is a double yarn which one yarn is straight and other is coiled over it

CAUSES
1. Bad piecing by robot
2. Improper mixing
3. Improper feeding (Feeding of two ends (instead of one )) in ring frame
4. Lashing -in ends in ring frame

EFFECT
1. Breaks during winding and warping
2. Causes streaks in the fabric

REMEDIES
1. proper maintenance of robot and operators are to be trained
in piecing methods(or) practices
2. proper mixing
3. Pneumatic ducts to be kept clean and properly set
  Discussion
time…

 Which of those discussed

yarn faults are widely
occurring in your factory..?

 Is there any different remedies

that you’ll made in addition to
the explained above..?
 1 STITCHING ON CONE PACKAGE DEFECTS

Ends not laid properly on the cone at reversal of yarn path

EFFECT
1. More end breaks in the subsequent process
2. Excessive yarn waste

CAUSES
1. Vibrating and wrongly set cone holder
2. Yarn coils wrapped round the base of cone holder
3. Traverse restrictors fixed at incorrect position
4. Improper alignment of tension brackets with the drum

REMEDIES
1. Maintenance cone winders to be good
2. Cone holder settings and alignment of tension
3. Brackets with drum to be carried out as frequently as possible
2 RIBBON WOUND CONE PACKAGE DEFECTS

Formation of ribbon like structure on the circumference of the cone

EFFECT
1. High level of slough off during unwinding
2. Excessive yarn waste
3. Uneven dye pick up in the case of dye packages

CAUSES
1. Winding spindle not revolving freely
2. Cone holders incorrectly set
3. Defective settings of cam switch
4. Improper traverse motion
5. Vibration of cone and traverse
6. Lint accumulation in builder cam groove

REMEDIES
1. Over hauling of cone winders to be periodically carried out
2. Anti ribboning mechanism to be checked at frequent interval
3. Free movement of the cone holders to be ensured by proper
lubrication
 3 SOFT BUILDS CONE PACKAGE DEFECTS

Unduly soft structure of cone

EFFECT
1. Overall density of package is lower
2. Soft packing either at the base or at the nose of cones

CAUSES
1. Improper alignment of cone holder and traverse
2. Insufficient unwinding tension
3. Inadequate cradle loading

REMEDIES
1. Unwinding tension to be maintained at 6 to 8% of single yarn
strength
2. Cradle pressure to be maintained to the optimum level
4 BELL SHAPED CONE PACKAGE DEFECTS

Cones which are tightly built at centre, presents a shape of bell

EFFECT
1. Excessive breaks during warping and winding processes

CAUSES
1. High yarn tension during winding
2. Cone holders incorrectly set to the winding drum
3. Damages in paper cone centre

REMEDIES
1. Quality of cones to be checked at that time of procurement
2. Optimum unwinding tension to be maintained
5 NOSE BUILDING PACKAGE DEFECTS

Bulging of bunches of the yarn at the nose of the cones

EFFECT
1. Slough during warping/unwinding
2. Excessive yarn waste in next process

CAUSES
1. Improper setting of cone holders to the winding drum
2. Damaged nose of the paper cones

REMEDIES
1. Periodical inspection of settings in winding machines
2. Operators to be instructed to adopt correct work practices
3. Avoiding usage of damaged paper cones
 6 COLLAPSED CONE PACKAGE DEFECTS

Collapse of the structure of the cone(paper cone)itself

EFFECT
1. Yarn breaks in warping process
2. Wastage increase in yarn preparation

CAUSES
1. Use of poor quality/damaged paper cones
2. Poor system of material handling
3. Maintaining non optimum unwinding tension

REMEDIES
1. Using of poor quality/damaged paper cones should be avoided
2. Winding operators should be trained by proper work methods
3. Proper material handling devices such as cone transport trolleys to
be used
4. Cone inserts to be used for paper cones
7 RING SHAPED CONE PACKAGE DEFECTS

Formation of ring shaped bulge across the cross section of the cone

EFFECT
1. More end breaks in the subsequent processes
2. Slough off during unwinding

CAUSES
1. Incorrect setting of the cone holder
2. Wrong placement tensioners in the tensioning assembly
3. Traverse of yarn affected due to defects in the grooves of the
drum

REMEDIES
1. Due to replacement of defective drums and stop motion wires
to be ensured
2. Periodic inspection of cone holder settings and tension
assembly to be carried out
8 SLOUGH OFF PACKAGE DEFECTS

Coils of yarn coming out of the ring cops in bunches at the time of unwinding

EFFECT
1. Increase in end breaks
2. Higher yarn waste

CAUSES
1. Improper ring rail movement
2. Worn builder cam
3. Loose package and excessive coils in the package
4. Soft build of cops
5. Improper empties fit on the spindles and slack tapes

REMEDIES
1. Ring rail movement to be set right
2. Optimum ratio of winding: bindings coils and optimum chase
length to be maintained
9 RING CUTS PACKAGE DEFECTS

Damaged layer on the surface of the ring cops

EFFECT
1. Excessive breaks during winding
2. More hard waste at winding

CAUSES
1. Spindle or empty cops wobbling
2. Use of lighter travelers and incorrect ratchet wheel
3. Movement of spindles to the rings not concentric

REMEDIES
1. Worn spindles to be replaced
2. Improper fit of empty cops with spindles to be avoided
3. Gauging of spindles with rings to be properly carried out
4. Use of right type traveler and ratchet wheel to be ensured
10 LOW COP CONTENT PACKAGE DEFECTS

Yarn content in the yarn is less.

EFFECT
1. Efficiency loss in ring frame
2. Drop in winding efficiency
3. More knots for a given length of wound yarn

CAUSES
1. Under utilization of bobbin height
2. Lower number of coils /inch
3. Higher chase length
4. Cop bottom bracket properly not set
5. Improper selection of ratchet
6. Ratchet pawl pushing number of teeth/movement in the ratchet wheel
7. Spinning empties wall thickness is high

REMEDIES
1. Optimum chase length, coil spacing and wall thickness of empty cops to be
ensured
2. Ratchet/pawl movement to be properly set
3. Free space of only 7.5mm to be maintained at the top and bottom of the cop
4. Free space only 0.75mm only to be maintained between full cops and the ring
11 IMPROPER BOBBIN BUILD PACKAGE DEFECTS

Step-like appearance of a cop.

EFFECT
1. Slough-off during doffing/winding
2. More breaks during unwinding(due to slough off)
3. Higher hard waste in winding

CAUSES
1. Improper combination of ratchet and pawl
2. Jerky ring rail movement(pocker rod movement to check)

REMEDIES
1. Ratchet and Ratchet/pawl movement to be accurately
arrived at taking into consideration
2. Count of yarn, ring dia and chase length
3. Lubrication of pocker rods at appropriate intervals to be
carried out
12 IMPROPER LEASING PACKAGE DEFECTS

One or more lease in the reeled hanks without leasing

EFFECT
1. More hard waste during post-reeling operations

CAUSES
1. Incorrect work practices during interlacing the leas with
the tie yarn
2. Not tying the starting and finishing ends of yarn reeled
from each peg with the tie yarn

REMEDIES
1. Reeling operators to be educated on the proper method
of leasing and their importance
13 LOOSE END IN HANKS PACKAGE DEFECTS

Broken threads or united ends in the hanks

EFFECT
1. More hard waste in post reeling operations
2. Difficulties during tying of ends

CAUSES
1. Damaged swift
2. Leaving the ends of yarn without tying during leasing
3. Wrong method of piecing during cop change

REMEDIES
1. Rough or damaged surfaces of swift to be avoided
2. Operators to be educated on the proper method
of tying the ends during the leasing
14 LONG/SHORT TIE YARNS PACKAGE DEFECTS

Leaving too long/too short length of yarn after leasing.

EFFECT
1. Entanglement of long tie yarns with reeled yarns
2. Higher time requirement for opening the knots of
the tied ends

CAUSES
1. Incorrect method of tying
2. Not trimming the ends after interlacing

REMEDIES
1. Tying practices of reeling operators to be improved
by proper training
15 MORE THREADS IN HANKS PACKAGE DEFECTS

More number of threads in one or more leas in the hanks.

EFFECT
1. More hard waste in post reeling process

CAUSES
1. Ineffective or absence of full doff stop motion
2. Damaged teeth at worm or worm wheel at reels

REMEDIES
1. Periodic inspection and replacement of
worm and worm wheel to be ensured
16 ENTANGLED THREADS PACKAGE DEFECTS

Entanglement of threads with in between leas.

EFFECT
1. More hard waste in post reeling operations
2. Higher time requirement for unwinding the hanks

CAUSES
1. Defective thread guide /swift/shifting mechanism
2. Ends, not being pieced, during replacement of cops or
during end breaks
3. Contaminated yarn cleaning brushes
4. In secured yarn guides and pegs

REMEDIES
1. Timely replacement of worn out yarn guides ,pegs and
brushes to be ensured
2. Operators to be trained to keep their machines clean
and tidy
17 LESSER HANKS IN KNOTS PACKAGE DEFECTS

Lesser number of hanks in the knots meant for bundling.

EFFECT
1. Incorrect judgment of the average count of
the yarn

CAUSES
1. Errors during grouping of hanks in to knots

REMEDIES
1. Operators to be educated on the proper
method of preparation of knots
18 NON UNIFORM SPACING PACKAGE DEFECTS

The spacing between the threads in the leas is non uniform.

EFFECT
1. More hard waste in post-reeling operations

CAUSES
1. Variation in the circumference at different part of the swift
2. Ineffective brake and full doff stop motion

REMEDIES
1. Diameter of the swift to be checked and corrected
periodically
2. Proper functioning of brake and full doff stop motion to be
ensured
19 NON UNIFORM SPACING PACKAGE DEFECTS

The spacing between the threads in the leas is non uniform.

EFFECT
1. Difficulties in tying of leas
2. More hard waste during unwinding

CAUSES
1. Defective and insecure thread guides
2. Improperly maintained yarn cleaning brushes

REMEDIES
1. Periodic cleaning of brushes by reeling operator to
be ensured
2. Damaged brushes to be replaced
3. Guides to be secured
POINTS TO BE NOTICED…

1. The main cases of warp yarn breakage (yarn fault) is improper

raw material mixing and cleaning in spinning because majority
percentage of yarn faults is weak yarn.
2. The number of breaks varied directly with the yarn count.

Reducing warp breaks on warping machines

uplift the efficiency of this process and the efficiency of weaving
machines, and finally enhances the quality of yarns and produced
fabrics.
Thank you
so much..!!