Optimizing Fabric Quality Through Detailed Dyeing Batch Analysis

Dyeing Batch Analysis Report

Report Details

Buyer: X

Batch No: Y

Dyeing Floor: Z

Order Quantity: [Specify] KG

Batch Quantity: [Specify] KG

Final Quantity: [Specify] KG

Process Loss: [Specify] %

Yarn Lot: B-7620

Shade: Purple

Fabrication: 20CC Compact STBPQ (100% Cotton)

Required Width: 77"

Actual Width: 79.5"–81"

Required GSM: 225

Actual GSM: 214–226

Required Drying Procedure: Tumble Dry

Enzyme Application: L = 0.5%

Dimensional Stability:

          Length (L): -5.0%

         Width (W): -6.0%

         Spirality (SP): 2.0%

Fastness to Washing:

Acetate: 4-5

Cotton: 4-5

Nylon: 4-5

Polyester: 4-5

Acrylic: 4-5

Wool: 4-5

Fastness to Water: N/A

Phenolic Yellowing: N/A

Perspiration: N/A

Cross Stain: N/A

Rubbing:

       Dry: 4-5

       Wet: 3

Pilling: N/A

Light: N/A

Saliva (Kids): N/A

Bursting Strength: 68 PSI

Process Route: Stentering, Compact & Relax Dry

Remarks: [PASS/FAIL]

Analysis Summary

This dyeing batch analysis report evaluates the performance and quality parameters of the fabric batch (Y) processed for Buyer X on Dyeing Floor Z. The fabric, identified as 20CC Compact STBPQ (100% Cotton) with yarn lot B-7620, was dyed in a purple shade. The analysis covers critical metrics such as dimensional stability, color fastness, fabric strength, and adherence to specified requirements.

Key Observations:

Width Compliance: The actual width (79.5"–81") exceeds the required width of 77", indicating a slight deviation from the specification. This may require adjustment in future processing to align with buyer requirements.

GSM Variation: The actual GSM (214–226) is marginally below and above the required GSM of 225, suggesting minor inconsistencies in fabric weight that could affect perceived quality.

Dimensional Stability: The fabric exhibits a shrinkage of -5.0% in length and -6.0% in width, with a spirality of 2.0%. These values are within acceptable industry standards for 100% cotton fabrics, indicating stable performance under standard conditions.

Color Fastness: Fastness to washing across all tested fibers (acetate, cotton, nylon, polyester, acrylic, wool) is rated 4-5, demonstrating excellent resistance to color fading during washing. Rubbing fastness is satisfactory, with a dry rating of 4-5 and a wet rating of 3, which is acceptable but could be improved for wet conditions.

Bursting Strength: The fabric achieved a bursting strength of 68 PSI, indicating robust structural integrity suitable for its intended application.

Process Adherence: The specified drying procedure (tumble dry) and enzyme application (L = 0.5%) were followed, with the process route involving stentering, compacting, and relax drying, ensuring proper fabric finishing.

Areas for Improvement:

The variation in actual width and GSM suggests a need for tighter control during processing to meet exact specifications.

Wet rubbing fastness (rated 3) could be enhanced to improve overall durability and aesthetic retention under wet conditions.

Missing data for order quantity, batch quantity, final quantity, and process loss percentage should be provided to complete the analysis and assess production efficiency.

Conclusion:

The batch demonstrates satisfactory performance in terms of color fastness, dimensional stability, and bursting strength, aligning with industry standards for 100% cotton fabrics. However, minor deviations in width and GSM, along with the wet rubbing fastness rating, warrant attention to ensure consistent quality. Based on the provided data, the batch is deemed [PASS/FAIL] pending confirmation of missing quantitative metrics and alignment with buyer expectations.

For further details or clarification, please contact the dyeing floor supervisor or quality control team.