Weaving Quality Control and Defects

Quality monitoring: Online inspection—optical sensors detecting warp breaks, weft defects (missing pick, wrong pick, thick/thin places, holes), stopping loom automatically, integrated in modern looms monitoring 100% of fabric. Offline inspection—fabric inspection machines with trained inspectors grading defects (4-point system: 1 point for <75 mm, 2 points 75-150 mm, 3 points 150-225 mm, 4 points >225 mm, max 4 points per defect, target <20-40 points per 100 m²). Common defects: Warp defects (broken ends, tight ends, missing ends, reed marks), Weft defects (broken picks, missing picks, slubs, weft bars), Weaving defects (starting marks, temple marks, loom bars, selvage defects), and Preparation defects (size spots, yarn contamination, wrong drawing). Defect prevention: proper preparation (sizing penetration 50-70% for protection without stiffness), tension control (±5% warp tension uniformity), environmental control (temperature 20-28°C, RH 60-75% reducing static and breaks), and preventive maintenance (timing verification, parts replacement schedules).