PACKAGE DEFECTS

Effect Causes Rectification

1. SLOUGH OFF : Coils of yarn combing out of the ring bobbins in bunches at the
time of unwinding

1. Increase in end 1. Improper ring rail 1. Ring rail movement should be set right
breaks movement 2. Optimum ratio of winding: Binding coils
2. Higher yarn 2. Worn builder cam optimum chase length to be maintained
waste 3. Loose package and
excessive coils in the
package
4. Soft built of bobbins
5. Improper bobbin fit
and slack tapes
2. RING CUTS : Damaged layer on the surface of the ring cops

1. Excessive breaks
1. Spindle or bobbin 1. Worn spindles to be replaced
during winding wobbling 2. Improper fit of bobbins with spindles to be
2. More hard waste
2. Use of lighter travellers avoided
at winding and incorrect ratchet 3. Gauging of spindles with rings to be
wheel properly carried out
3. Movement of spindles to 4. Use of right of travellers and ratchet to be
rings not concentric ensured
3. LOW COP CONTENT : Yarn content in the ring cop is less

1. Efficiency loss in
1. Under utilization of 1. Optimum chase length, coil spacing and
ring frame bobbin height wall thickness of ring bobbins to be ensured
2. Drop in winding
2. Lower number of 2. Ratchet / pawl movement to be properly set
efficiency coils/inch 3. Free space of only 7.5mm to be maintained
3. Higher knots for
3. Higher chase length at the top and bottom of the cop
a given length of
4. Cop bottom bracket 4. Free space of only 0.75mm to be
wound of yarn properly not set maintained between full bobbin and the ring
5. Improper selection of
ratchet/pawl movement
6. Use of ring bobbins with
higher wall thickness
4. IMPROPER BUILD : Step-like appearance of the cop
 PACKAGE DEFECTS
Effect Causes Rectification

1. Slough-off during 1. Improper combination of 1. Lubrication of poker rods at appropriate

doffing ratchet and pawl intervals to be carried out
2. More breaks 2. Jerky ring rail movement 2. Ratchet and ratchet/pawl movement to be
during unwinding accurately arrived at taking into
3. Higher hard consideration count of yarn, ring dia and
waste in winding chase length
5. STITCHING ON CONE : Ends not laid properly onto the cone at reversal of yarn
path

1. More end breaks1. Vibrating and wrongly 1. Overhauling of cone winders to be

in the set cone holder periodically carried out
subsequent 2. Yarn coils wrapped 2. Cone holder settings and alignment of
process round the base of cone tension brackets with the drum to be carried
2. Excessive yarn holder out as frequently as possible
waste 3. Traverse restrictors
fixed at incorrect
position
4. Improper alignment of
tension brackets with
the drum
6. RIBBON WOUND CONE : Formation of ribbon like structure on the circumference
of the cone

1. High level of 1. Winding spindle not 1. Overhauling of cone winders to be

slough off during evolving freely periodically carried out.
unwinding 2. Cone holders incorrectly 2. Anti ribboning mechanism to be checked at
2. Excessive yarn set frequent interval
waste 3. Defective settings of 3. Free movement of cone holders to be
3. Uneven dye pick cam switch ensured by proper lubrication
up in the case of 4. Lint accumulation in
dye package builder cam groove
7. SOFT BUILD OF CONE: Unduly soft structure of cone
 PACKAGE DEFECTS
Effect Causes Rectification

1. Overall density of 1. Improper alignment of 1. Unwinding tension to be maintained at 6 to

the package is winding spindle to 8 % of single yarn strength
lower winding drum 2. Cradle pressure to be maintained at
2. Soft packing 2. Insufficient unwinding optimum level
either at the tension
base or at the 3. Inadequate cradle
nose of the cone loading
8. BELL SHAPED CONE : Cones which are tightly built at centre presents a shape of
bell

1. Excessive breaks
1. High yarn tension during 1. Quality of cones to be checked at the time
during winding of procurement
subsequent 2. Cone holders incorrectly 2. Optimum unwinding tension to be
processes set to winding drum maintained
3. Damages in paper
cones at the centre
9. NOSE BUILDING : Building of bunches of yarn at the nose of the cones

1. Slough off during 1. Improper setting of cone

1. Periodical inspection of settings in winding
warping holder to winding drum
machines
2. Damaged nose of the
2. Tenters to be instructed to adopt correct
paper cones work practices
3. Avoiding use of damaged paper cones
10. COLLAPSED CONE : Collapse of the structure of the cone itself

1. Excessive break 1. Use of poor quality or 1. Winding tenters to be trained on correct

during warping damaged cones work practices
2. High level of hard 2. Poor system of material 2. Proper material handling devices such as
waste handling cone transport trolleys to be used
 PACKAGE DEFECTS
Effect Causes Rectification
3. Maintaining non 3. Cone inserts to be used for paper cones
optimum unwinding
tension
11. RING SHAPED CONES : Formation of ring shaped buldge across the cross
section of the cone

1. More end breaks 1. Incorrect setting of cone 1. Due replacement of defective drums and
during holder stop motion wires to be ensured
subsequent 2. Wrong placement of 2. Periodic inspection of cone holder settings
processes tensioners in the and tension assembly to be carried out
2. Slough off during tensioning assembly
unwinding 3. Traverse of yarn
affected due to defects
in the grooves of the
drum
12. IMPROPER LEASING : One or more leas in the reeled hanks without leasing

1. More hard waste 1. Incorrect work practices 1. Reelers to be educated on the proper
during post- during interlacing the method of leasing and their importance
reeling leas with the tie yarn
operations 2. Not tying the starting
and finishing ends of
yarn reeled from each
peg with the tie yarn
13. LESS THREADS IN HANKS : Lesser number of threads in the hanks reeled

1. More hard waste 1. Incorrect setting of 1. Proper condition and setting of rack and
during rack and index wheel index wheel to be ensured
subsequent 2. Broken index wheel
processes
14. LOOSE ENDS IN HANKS : Broken threads or untied ends in the hanks
 PACKAGE DEFECTS
Effect Causes Rectification

1. More hard waste1. Damaged swift 1. Rough or damaged surfaces of swift to be

during post- 2. Leaving the ends of avoided
reeling yarn without tying 2. Tenters to be educated on the proper
operations during leasing method of tying the ends during leasing
2. Difficulties during
3. Wrong method of
tying of ends piecing during cop
change
15. LONG/SHORT TIE YARNS : Leaving too long / short length of yarns after
leashing

1. Entanglement of 1. Incorrect method of 1. Tying practices of reelers to be improved by

long tie yarns tying proper training
with reeled yarns 2. Not trimming the ends
2. Higher time after interlacing
requirement for
opening the
knots of the tied
ends
16. MORE THREADS IN HANKS : More number of threads in one or more leas in
the hanks

1. More hard waste 1. Ineffective or 1. Periodic inspection and replacement of

during post- absence of full doff stop worm and worm wheel to be ensured
reeling motion
operations 2. Damaged teeth at
worm or worm wheel at
reels
17. ENTANGLED THREADS : Entanglement of threads within and between leas

1. More hard waste 1. Defective thread guide / 1. Timely replacement of worn yarn guides,
during post- swift / shifting pegs and brushes to be ensured
reeling mechanism 2. Reelers to be trained to keep their
 PACKAGE DEFECTS
Effect Causes Rectification
operations 2. Ends, not being pieced , machines clean and tidy
2. Higher time during replacement of
requirement for bobbins or during end
unwinding the breaks
hanks 3. Contaminated yarn
cleaning brushes
4. Insecured yarn guides
and pegs
18. LESSER HANKS IN KNOTS : Lesser number of hanks in the knots meant for
bundling

1. Incorrect 1. Errors during 1. Tenters to be educated on the proper

judgement of the grouping of hanks into method of preparation of knots
average count of knots
the yarn
19.LESSER LENGTH OF YARN : Lesser length of yarn in the hanks reeled

1. More hard waste 1. Variation in 1. Diameter of the swift to be checked and

during post- circumference at corrected periodically
reeling different part of the 2. Proper functioning of break and full doff
operations swift stop motion to be ensured
2. Ineffective break
and full doff stop
motion
20. NON UNIFORM SPACING : The spacing between the threads in the leas is
non uniform

1. Difficulties in 1. Defective and in 1. Periodic cleaning of brushes by the

tying of leas secured thread guides reelers to be ensured
2. More hard 2. Improperly 2. Damaged brushes to be replaced
waste during maintained yarn 3. Guides to be secured
unwinding cleaning brushes