NEWS & CSR

Common Issues in Knitted Fabric (Fabric Defects) and How to Prevent Them

30 Des 2025 | 124 Views | News Category: Education

In the textile production world—especially in knitted fabrics—fabric defects are more than just technical terms. They represent quality challenges that can lead to product rejection, increased costs, and poor customer experience.
For those of you who prioritize production quality, understanding and preventing knitted fabric defects is a crucial step in maintaining your brand’s reputation and competitiveness.

What Are Knitted Fabric Defects?

Knitted fabric defects refer to any irregularities in knitted fabrics that affect their appearance, structure, or performance—ranging from uneven lines to holes that reduce both aesthetic value and functionality. These defects can occur at various stages of production, from yarn spinning to final finishing.

Common Types of Knitted Fabric Defects

Drop Stitches (Unexpected Holes)

Drop stitches appear as small to large holes when the yarn fails to properly interlock within the knitted structure.

Causes:

Improper yarn tension
Suboptimal machine settings
Low-quality yarn or yarn with imperfections

How to Prevent:

Ensure uniform yarn tension across all feeders.
Use high-quality yarn free from slubs, knots, or neps.
Perform regular inspections on knitting machines.

Barré (Unwanted Horizontal Lines)

Barré refers to the unintended appearance of horizontal stripes or bands on the fabric, often visible as variations in color or texture.

Causes:

Differences in yarn properties within the same batch
Inconsistent yarn tension
Variations in yarn diameter or curvature

How to Prevent:

Use yarns from the same lot throughout production.
Maintain consistent tension control across all feeders.
Regularly calibrate and adjust machine settings.

Skewing and Spirality (Fabric Distortion)

Skewing occurs when the knitted courses deviate from the ideal 90° angle relative to the fabric width, while spirality causes the fabric to twist or appear slanted.

Causes:

Unbalanced yarn twist
Inappropriate tension and spinning parameters

How to Prevent:

Use yarns with twists and parameters that meet factory specifications.
Conduct machine setting trials to ensure dimensional stability before mass production.

Imperfections and Contaminations

Imperfections such as slubs, knots, or neps appear on the fabric surface due to uneven yarn quality. Contamination occurs when foreign fibers become embedded in the knitted structure.

Causes:

Poor yarn quality
Foreign particles in the production environment

How to Prevent:

Apply strict standards for yarn raw materials.
Maintain a clean production area and conduct inspections prior to processing.

Pilling and Snagging (Uneven Fabric Surface)

Pilling: The formation of small fiber balls on the fabric surface after friction.
Snagging: Loops of yarn pulled out from the fabric surface, creating an untidy appearance.

Causes:

Friction during use or finishing processes
Rough or damaged machine surfaces

How to Prevent:

Apply anti-pilling treatments when necessary.
Ensure all machines are clean and free from sharp or rough surfaces.
Use gentle finishing processes appropriate to the fabric’s characteristics.

Why Is Defect Prevention Important?

Minimizing knitted fabric defects is not merely about aesthetics—it directly impacts production value, customer satisfaction, and operational efficiency. Fabric defects can lead to product rejection, rework costs, and damage to your brand’s reputation in the eyes of buyers.

Integrated Prevention Strategies

To significantly reduce knitted fabric defects, you can implement the following strategies:

Quality control at every stage: From yarn inspection to finished products.
Routine machine audits: Ensure all knitting machine components operate properly.
Process standardization: Clear SOPs for tension, feed rate, finishing, and inspection.
Team training: Well-trained operators are more likely to detect defects early.

With these strategies in place, you can lower rejection rates while improving overall production efficiency.

Dealing with knitted fabric defects is an inevitable part of knitted fabric production. However, with a solid understanding of defect types and how to prevent them, you can enhance product quality—from raw materials to final finishing.
Early prevention not only reduces costs but also strengthens customer trust in your brand.

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