(QA）Analysis of Causes and Solutions for Common Fabric Problems --Causes and Solutions for Excessive Joints in Fabric Base Cloth

Analysis of Causes and Solutions for Common Fabric Problems

--Causes and Solutions for Excessive Joints in Fabric Base Cloth

Question 1: In one batch of fabric, there are multiple base fabric joints. What causes this?  

Answer:  

Standard industry specifications for the length of a single roll of base fabric are as follows:  

- Single-sided fleece, non-woven cotton, and non-woven fabric: approx. 100 meters per roll.  

- Chunyafaxing (spring-yarn type) base fabric: approx. 500 meters per roll.  

However, typical dyeing, finishing, and lamination production batches are processed in a single setting (one jigger/range) at approx. 1,000 meters.  

This results in multiple base fabric joints in one batch.  

- For single-sided fleece / non-woven cotton / non-woven fabric, splicing naturally produces 9 joints – this is normal for the industry.  

- For Chunyafaxing base fabric, splicing 2 rolls produces only 1 joint.  

Summary:  

Single-sided fleece, non-woven cotton, and non-woven fabric have relatively short single-roll lengths. When processed in standard 1,000-meter batches, 9–10 joints per batch are not a quality defect; they are normal and unavoidable joints caused by the combination of raw material specifications and production batching practices.  

Question 2: How can we control / handle the issue of excessive base fabric joints during the final quality inspection stage?  

Answer:Quality inspection procedures – specific measures:  

1. Incoming inspection of base fabric – pre-screen original rolls  

- During receiving and inspection, prioritize rolls that are longer, free of holes, and without defects for batching.  

- Separate overly short rolls, rolls with many head/tail defects, or damaged edges – do not mix them into bulk production batches. This reduces ineffective joints and defective joints.  

- Cut off defective sections at the head/tail of each roll before splicing, to avoid defects at the joint location.  

2. Splicing process quality control  

- Require uniform splicing standards in the workshop:  

  - Joints aligned flat, no wrinkles, no skewing, no excessive thickness from overlapping.  

  - Strong stitching – no thread loosening or seam opening.  

  - Good straightness of the joint to avoid subsequent weft skew or ridging at the splice.  

- Prohibit diagonal splicing, random splicing, or overly wide overlaps. Use narrow, flat splicing uniformly to reduce joint thickness marks.  

3. Final fabric inspection – mark every joint  

- During inspection, mark each joint clearly (label, color mark) and record the meter position.  

- Note: joint position, flatness, defects, and whether it can be used for first-quality products.  

- Defective joints (wrinkled, skewed, holed, thick ridged) are directly marked as second quality.  

4. Cutting and spreading in furniture production – precise avoidance (most critical)  

- Provide the cutting department with the recorded joint positions (meter marks). During lay planning, directly avoid those positions.  

- Use joint sections exclusively for small accessories, edge banding strips, small lining pieces – never for large panels, shoe uppers, or visible front surfaces.  

- When spreading fabric, break the lay at the joint – do not force it flat or try to use it under tension.  

5. Quality grading  

- Smooth, good-quality joints: downgrade to linings, non-visible areas, or accessories.  

- Joints with wrinkles, thick marks, or skewing: directly classify as second-grade or scrap – do not use in first-quality production.  

- For Chunyafaxing (500 m/roll): few joints, only need to focus on flatness of the joints.  

6. In-process patrol + final inspection control  

- Randomly inspect joints during sewing or lamination – check for bubbling, ridge marks, or show-through.  

- Final inspection of finished goods: focus on whether any joint appears on the front side, or if there are ridge marks, wrinkles, or skewing. If problems exist, pull out for rework or downgrade.  

Summary – one sentence:  

The number of joints cannot be completely eliminated, but by pre-screening rolls → standardizing splicing → marking joints during inspection → avoiding joints during cutting → graded usage, we can ensure that joints are not used in large panels, not on the front side, and do not cause quality complaints – minimizing the impact.