How Can Underwear Factories Deal With the Problem of Fabric Color Difference?

In the production of underwear, the quality of the fabric is of utmost significance. And the issue of color difference is a crucial factor affecting the quality of underwear. It not only impacts the aesthetic appearance of the underwear but may also reduce consumers' purchasing intention. The color difference problem of the fabric might cause the same piece of underwear to display different colors in different areas, severely affecting the overall attractiveness and quality perception of the product. Such color difference problems could make consumers dissatisfied with the product and even have an impact on the brand image. Thus, underwear factories must adopt effective measures to prevent color differences in the same piece of underwear and ensure product quality.

In actual production, the color difference of fabrics may be caused by multiple reasons. For example, the uneven distribution of dyes on the fabric, different degrees of color fixation and variations in color shade. All of these factors may lead to color differences in fabrics, which in turn will affect the production quality of underwear.

When there is a color difference in the underwear fabric, the underwear factory needs to take a series of effective measures during the production and sewing process to avoid the problem of color difference in the same pair of underwear. The following are some specific suggestions:

I. Color Difference Detection and Classification

1. Color Difference Detection:

Use a color measuring instrument, a color difference meter, or an international standard color matching light box to conduct color difference detection on fabrics. Once color differences are found, adjust the dyeing proportion in a timely manner or look for the causes. Analyze whether the color differences are caused by different batches of fabrics, or by cylinder differences, formula errors, etc.

2. Color Difference Classification:

Identify the types of color differences, such as cylinder differences, differences between the edge and the center, and differences between sections. For different types of color differences, adopt different solutions. Return the fabrics with relatively large color differences to the dyeing factory for color repair. Discover and handle color difference problems in a timely manner to ensure that the fabric colors meet the quality standards.

II. Control of Raw Materials and Dyeing

1. Procurement of Raw Materials

Purchase yarns from the same cotton yarn factory and use cotton blended according to the same batch and place of origin to weave gray fabrics. Put them into dyeing separately according to the batch numbers and adjust the materials used in the process. This ensures the consistency of the quality of raw materials at the source and lays the foundation for avoiding color differences.

2. Optimize the Dyeing Process

Select Appropriate Dyes and Auxiliaries: Based on the material and characteristics of the fabric, choose dyes and auxiliaries that have good compatibility, high dye uptake rate and strong color fastness. For example, for cotton underwear fabrics, reactive dyes usually can achieve better dyeing effects and color stability; while for special materials like lace, special dyes and auxiliaries may be required to ensure the dyeing quality.

Precisely Control Dyeing Parameters: Strictly control all parameters in the dyeing process, such as temperature, time, pH value, etc. Determine the optimal dyeing process parameters through small-scale tests and pilot-scale tests, and ensure their strict implementation in mass production. Taking temperature as an example, different dyes have different dye uptake rates at different temperatures. Precise control of temperature can effectively reduce color differences.

III. Cutting and Layout Strategies

1. Cutting Strategies:

For cylinder differences, if the color difference is not significant and can be confirmed by the client, separate handling can be carried out during cutting and sewing to ensure that different batches of fabrics are not used for the same pair of underwear.

For differences between the edge and the center as well as differences between the head and the tail, special treatment is required during cutting.

2. Layout Strategies:

Adopt a special marker layout to ensure that there is no color difference in the main parts (such as the front and back of the underwear, the waist, etc.).

For slight differences between the edge and the center, the impact of color difference on the finished product can be reduced through layout adjustments.

If the color difference problem cannot be solved through layout, it is necessary to consider removing the fabric edges with relatively serious color differences and then using the corrected marker for layout.

IV. Monitoring and Adjustment during the Production Process

During the sewing process of underwear, conduct real-time monitoring and record the colors of semi-finished products and finished products.

Discover color changes in a timely manner and make adjustments to ensure the stability and continuity of the production process.

Regularly clean and maintain the sewing equipment to prevent pollutants such as oil stains and dust remaining on the equipment from contaminating the fabric and affecting the fabric color. Especially when sewing light-colored underwear, the cleaning of the equipment is particularly important.

V. Staff Training and Quality Inspection

1. Staff Training:

Conduct regular training for staff on color difference control.

Improve the staff's ability to identify and handle color difference problems.

2. Quality Inspection:

a. Multi-light Source Detection

Set up multiple light source environments: Establish a detection environment that includes multiple light sources such as natural light, D65 standard light source, and TL84 fluorescent light source. Since people's visual perception of colors varies under different light sources, detecting under multiple light sources can help discover potential color difference problems more comprehensively.

Multi-angle observation: During the inspection, not only should the fabric colors be observed from the front, but also from different angles, such as at a 45-degree tilt, etc., to ensure that the colors of the underwear remain consistent under various wearing and display conditions and avoid visual color differences caused by light reflection and refraction.

b. Sampling Inspection and Comparison by Batches

Reasonable sampling inspection: Conduct sampling inspections on each batch of fabrics and finished underwear according to a certain proportion to ensure that the inspection results are representative. For large-volume orders, the stratified sampling method can be adopted to improve the accuracy of the inspection.

Comparison with the standard color: Compare the colors of the sampled fabrics and finished products with the previously retained standard color cards or approved samples. Those that exceed the allowable range of color difference should be adjusted or dealt with in a timely manner. Meanwhile, compare the products of different batches to ensure the color consistency among batches.

VI. Cooperation and Communication with Suppliers

1. Strictly Screen Suppliers

Qualification and Reputation Review: Give priority to selecting suppliers with a good reputation in the industry, rich production experience and a sound quality management system. Check their past cooperation cases and customer reviews to understand their performance in providing fabrics with good color difference control. Suppliers that have long-term cooperation with well-known underwear brands and have no major complaints about color differences are more trustworthy.

Color Card and Sample Confirmation: Ask suppliers to provide accurate color cards and a sufficient number of fabric samples. Under different light source conditions, such as natural light and fluorescent light, carefully compare the colors of the color cards and samples to ensure the accuracy and consistency of the colors. Meanwhile, keep the color cards and samples as the color reference standards for subsequent production.

2. Clarify the Standards and Requirements for Color Difference

a) Formulate Quantitative Indicators: Based on the positioning of underwear products and market demands, specific allowable ranges for color difference should be formulated, such as keeping the △E value (color difference value) within 1.0, etc. These quantitative indicators can provide clear bases for subsequent inspections and acceptances, avoiding problems caused by differences in subjective judgments.

b) Communicate Special Color Requirements: For some special colors or trendy colors, in-depth communication with suppliers should be carried out regarding their dyeing processes and possible color difference risks. Ensure that suppliers are capable of stably producing fabrics that meet the color difference standards as required. For example, for the popular Morandi color series in the current season, it is necessary to clarify its special requirements for color fastness and color difference.

All in all, underwear factories should continuously improve all aspects of the production process and keep perfecting the color difference control measures so as to enhance product quality, meet consumers' needs and strengthen brand competitiveness. Only in this way can they remain invincible in the fierce market competition.

• Xiamen Unitex Trade CO.,LTD.
• Website: www.unitexunderwear.com
• E-mail: [email protected]
• Tel: 0086-186 5081 3853