Development of System for Online/Offline

Quality Control of Nonwoven Fabrics/Functional

Fabrics
using Digital Image Processing Techniques

Ph.D. Synopsis

Submitted To
Gujarat Technological University
For The Degree
of
Doctor of Philosophy
in
Textile Engineering
By

Ms. Krishma S. Desai

Batch: 2011
Enrollment No: 119997125001
Textile Engineering

Supervisor Co-Supervisor
Prof. (Dr.) P. A. Khatwani Dr. Hamed SariSarraf
Sr. Professor & Head, Professor, Electrical and
Department of Textile Computer Engineering,
Technology, Sarvajanik Texas Tech University,
College of Engg. & Tech., Box
Surat, India 43102 Lubbock, TX
794093102
Title of the thesis:
Development of System for Online/Offline Quality Control of Nonwoven
Fabrics/Functional Fabrics using Digital Image Processing Techniques

Abstract:
As a result of globalization & also increasing competition, it has become very important
for any industry to develop solutions regarding the quality of products. Effective
monitoring and control, better data predictions, quick response to query is necessary for
effective Quality Control. The research work intended here is to develop an
online/offline quality control system for different types of nonwoven fabrics/variety of
functional fabric by developing mathematical models and using digital image
processing.

Brief description on the state of the art of the research topic:

Functional Fabrics or more commonly known as the Technical Textiles are the fabrics
manufactured primarily for their functional/technical and performance properties rather
than just their aesthetic appearance. The qualities and properties of
nonwoven/functional fabrics are influenced largely by factors like type & structure of
raw material, type of fabric-woven, knitted, nonwoven, special fabrics, etc. which also
influence the surface texture of the fabric. Thus the visual inspection of the fabrics is an
important aspect in assessing the quality of the fabrics.

Human Visual Inspection of fabrics have been a criteria for Visual Assessment of fabric
quality in the Textile Sector since long. It included the detection of fabric defects
generally. However, this method cannot detect more than 60% of the overall defects for
the fabric if it is moving at a faster rate and thus the process becomes insufficient and
costly. Therefore, automatic fabric defect inspection is required to reduce the cost and
time waste caused by defects.

Available commercial systems comprises[31] of visual inspection systems, which

detects some of the defects in the fabrics mostly used for apparels. These systems are
too expensive for small companies. Therefore, a lot of studies are being done to use PC-

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based real time inspection systems, which gives the benefits of low cost and high
detection rate. It also offers the scope of experimenting for improvement in assessment
of the fabrics. It offers a scalable open architecture and can be manufactured at
relatively low cost using off-the-shelf components was required. Also this type of
systems for quality control would give the benefits of low cost.

On going through extensive literature survey in the said area it has been found that the
use of real time vision based/ image recognition or processing has been an effective tool
for detection of variation in textiles. The various approaches after the detection of the
defects for effective quality control of textiles are discussed below:

A paper[12] by Image Ghith, Fayala & Abdeljelil on Assessing Cotton Fiber Maturity
and Fineness proposes a maturity analysis of fibres by image analysis, where structural
variability is studied for analysing maturity and fineness. Another paper[9] by Das,
Isthiaque & Mishra shows the studies carried out for assessing the fibre openness using
Image Analysis Technique. Image analysis is an attractive alternative to existing
systems for investigating some quantitative fibre characteristics. It is quick, reliable and
unbiased technique which is used to evaluate fibre characteristics.

A lot of studies have been done in the area of defect detection for quality control in the
area of woven fabrics[1], [4], [7], [14]. Initial studies in this area had been done in the
area of woven fabrics in 1999, using a defect segmentation algorithm[13]. Then after
many algorithm using local threshold technique, using various filters, etc. has been
studied upon for defect detection in the woven fabrics mainly for the ones being used
for the apparel.

A limited study has been done in the area of assessing structural variability in the area
of nonwovens as well as functional fabrics. Also the studies done in the area of
nonwovens is largely limited to measurement of fibre orientation in the web rather than
defect detection & analysis, which becomes a complex process due to the fibrous
structure of nonwovens. The Studies [36] proposed by S. Hariharan, S. A. Sathyakumar,
P. Ganesan on measuring of fibre orientation in nonwovens using image processing but
not on detection of the faults and their classification. Paper describes the application of

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image processing techniques for measuring the fibre orientation in nonwovens. Spatial
uniformity of fibrous structures have been described statistically by using index of
dispersion.

Results shows the technique is capable to identify variation in geometrical dimensions

of very small textile objects. By elaborating the digitization algorithm along with
numerical methods would give solutions for obtaining characteristics of nonwovens and
thus improving the quality.

Definition of the Problem:

The survey of the papers gives an idea of the different approaches that have been
considered in designing quality control systems in the area of textiles. The study shows
that limited studies have been carried out for defect detection of nonwovens and
functional fabrics and therefore offers scope of further research in the said area.

With the increase in number of applications of technical textiles in different areas

during the days to come, it becomes necessary to design and develop the system to
check the quality of such varieties of fabrics in much shorter time and with utmost
accuracy.

The visual uniformity of the fabrics will be detected by a cost and quality effective
device to be developed during this research work.

Objective and Scope of work:

 To develop cost and quality effective system for targeting mainly the growing
Indian Technical Textile Market.
 To help the user in selection of proper quality of nonwoven/functional fabrics
for specific end use applications.
 To help the user to avoid unnecessary wastage of time and materials, which
otherwise would be due to wrong selection of materials for any specific
application

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  Very bright prospects ahead for the system to be developed considering very
high market growth from 10 billion dollars in 2009 to expected 31 billion dollars
in 2020.

Original contribution by the thesis:

The entire work is the original work, with the filing of patent under process and well
supported by the research papers. The developed system has been considered as a
combination of different similar systems available for such applications.

Methodology of Research, Results / Comparisons:

We have used qualitative as well as formulative approach for this research work. The
structure/qualities and properties of nonwoven/functional fabrics are influenced largely
by factors like type & structure of raw material, type of fabric-woven, knitted,
nonwoven, special fabrics, etc. which also influences the surface texture of the fabric.

Process Flow Chart of Developed System (Fig. 1):

Fabric
Device Development Image Acquisition
Sampling

Image Processing
Classification • Enhancing Images
• Extracting Features

Fig. 1: Process Flow Chart of Developed System

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Device Development for Quality Monitoring(Fig. 2):

Fig. 2: Device for Quality Monitoring

Sampling:
• Fabric Sampling.
• Image Acquisition using the developed Device

Fabric Sampling:
6 different varieties of functional fabric including woven as well as nonwoven fabrics
were manufactured for the study. The defects obtained in the manufactured fabric were
a result of the fabric manufacturing process and were assessed visually as well as with
the software developed using the proposed algorithm using MATLAB. However, the
experts from IIT had suggested to consider only one variety of fabric preferably
spunbond nonwoven fabric during the Research Week held during month of April 2015
at Gujarat Technological University, Ahmedabad. They had also suggested to consider
some of the major defects occurred during the manufacturing of spunbond fabrics. Also,
validate the results so obtained by taking multiple images of same defects. After
considering the inputs from the experts of IIT, the study has been narrowed down to 2

5
varieties of functional fabrics i.e. Woven Geotextiles & Spunbonded Nonwovens. 7
types of defects in each variety has been focused on in the study.

The details of the samples are shown as below:

• Woven – Geotextiles - Manufactured at M/s. Technofab, Udhana Magdalla Road,
Surat
• Machine Specifications:
– Sulzer Projectile Loom
• PU model loom
• 3.5 m and 5 m width
• Speed-230 rpm for 3.5 m & 180 rpm for 5 m

Sample epi x ppi warp x weft Denier GSM

Name

G1 38 x 24 720 x 400 160

G2 38 x 26 400 x 400 120

G3 34 x 24 800 x 800 215

G4 38 x 24 660 x 660 210

G5 21 x 21 2000 x 2000 290

G6 36 x 24 720 x 720 210

G7 34 x 26 1000 x 1000 220

List of defects identified:

Sr. Fabric Definition Principal Causes Remedy
No. Defect
1. Missing There may be one If the broken ends are This defect can be
End end or a group of not mended minimised (a) by
(Chira) ends missing in immediately by the minimising missing
the fabric. operator, these missing ends in the weaver’s
ends will occur in the beam & (b) by
fabric. providing an efficient

6
 warp - stop motion on
a loom.
2. Slubs Thick untwisted Variation in draft during Set the draft as per the
(Warp) portion in warp spinning. requirement.
yarn
3. Stain These stains are improper material By proper material
(Daggi) due to lubricants handling, bad oiling & handling as well as
or dust. cleaning practices good oiling & cleaning
practices, this defect
can be avoided.
4. Slubs Thick untwisted Variation in draft during Set the draft as per the
(Weft) portion in weft spinning. requirement.
yarn
5. Missing It is a strip which It is caused by faulty let This defect can be
Pick extends across the - off & take - up remedied by proper
(Jerky) width of fabric & motions. Also, if the setting of let - off &
has the pick loom is not stopped take - up motions &
density lower immediately in case of also by using an
than the required weft break, few picks efficient brake -
one. are liable to be missed motion.
in the fabric.
6. Gout Foreign matter It is caused when the This defect can be
woven in a fabric hardened fluff or foreign remedied by
by accident. matter such as pieces of preventing the foreign
Usually lint or leather accessories, matter from falling
waste. pieces of damaged onto the warp between
pickers etc., is woven the reed & the fell of
into the texture of the the cloth.
fabric.

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• Nonwoven-spunbonded- Manufactured at M/s. Wovlene Tecfab India, A-42/5,
Ichchhapore G.I.D.C, Near GEB Substation, ONGC Road, Hazira, Surat-394510.
• Machine Specifications:
– Chinese make spunbonded machine -1.6 m width
– Capacity : 5 tonnes/day
– GSM range :10 -200

Sample Name GSM

NS1 40

NS2 60

NS3 60

NS4 60

NS5 60

NS6 85

NS7 120

NS8 135

NS9 60

NS10 60

NS11 80

List of defects identified:

Sr. Fabric Definition Principal Causes Remedy

No. Defect
1. Drops / Fused fibres on Breaking of bundle of Proper setting of draw
bond point
surface filaments during the ratio.
fusion
process.
2. Pinholes Very small Damaged surface of Filing of surface of
holes in fabric delivery roller. roller.

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3. Wrinkles Wrinkle Improper tension Maintaining uniform
formation across the width of tension.
fabric.
4. Hard Fused Breaking of filaments Proper setting of draw
filaments
filaments on during the process. ratio.
surface
5. Hole Holes in fabric/ Improper supply of Maintaining proper
web polymeric material supply of polymeric
across the width of material across the
fabric, blockage of width of fabric, cleaning
spinnerette holes. of spinnerrrate.
6. Calendar Cut marks due Rough surface of Polishing of surface of
cut
to calendaring calendar roll. roller.
7. Thin spots Low density of Improper supply of Maintaining proper
fibres in a polymeric material supply of polymeric
particular area across the width of material across the
fabric. width of fabric.

Fabric Image Acquisition: More than 200 images of different fabric samples were
captured using CMOS camera.

Methodology involved in Image Processing:

The captured images were processed using MATLAB. Various parameters like mean,
sd, histogram of the intensity values were studied for estimating & identifying the
standard images. The images of the samples with defect were then processed for
obtaining the defect statistics.

The proposed algorithm will check for variability and give defect statistics and classify
as per Defect Area. It will also check for no. of Defects in the Fabric Lot and give %
Defects in the Fabric. On the basis of the defect statistics a fabric grading system has

9
been developed which will classify the fabric for specific application. The sequence of
steps followed in the processing of the images is shown in fig.3.

Image of Fabric

Gray Level Conversion

Contrast Adjustment

Histogram

Thresholding

Binary Image

Morphological Operations

Feature Extraction

Classification

Fig. 3: Steps involved in Image Processing of Images for Defect Classification

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Accuracy of Detection of Variability:
The Defect Statistics obtained from the software were compared with the values
obtained by manual visual examination of the defects. The defective percentage
accuracy of the results for geotextiles and spunbonded fabrics has been shown in Fig. 4
& Fig 5.

% Accuracy
100
90
80
70
60
50
40
% Accuracy
30
20
10
0
Missing Slubs Stain Slubs Missing Gout
End (Warp) (Daggi) (Weft) Pick
(Chira) (Jerky)

Fig. 4: % Accuracy for Geotextiles

% Accuracy
120
100
80
60
40
% Accuracy
20
0

Fig. 5: % Accuracy for Spunbonded

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Validation of Results:
Multiple Images of same samples had been taken to validate the results. CV% of the
defect statistics obtained for multiple images of each type of defect was calculated.
About 5-10% CV was found.

Fabric Grading:
On the basis of the defect parameters obtained as result of the processing of images of
the fabric lot & considering the proposed classification of defect, a fabric grading
system was developed. The Defect Classification is shown in Table 1.

Defect Name (DN) Woven Geotextile Spunbonded Nonwoven

Missing End (Chira) Drops / bond point
fusion
Slubs (Warp) Pinholes
Stain (Daggi) Wrinkles
Slubs (Weft) Hard filaments
Missing Pick (Jerky) Holes
Gout Calendar cut
Thin Spots
Defect Size (DS) Mendable- 10 % Defective Area
Permissible- 30% Defective Area
Critical - 60% Defective Area
Rejected - 80% Defective Area
Defect Frequency (DF) Frequency of occurrence of defects
Defect Orientation (DO) Machine Direction/Warp Way
Cross Direction/Weft Way

Table 1

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The Proposed Grading System is shown below:

Grade of Fabric Proposed Performance of Fabric

A (Best) The defect has no or very negligible influence, the fabric can thus be
used for suggested applications.
B (Good) Substandard applications of suggested areas are possible with this
grade of fabrics.
C (Poor) Can be considered after repairing or taking preventive measures for
suggested areas of applications.
D (Rejected) Not to be considered for any suggested applications.

Achievements with respect to objectives:

Successfully designed & developed prototype of device well supported with the user
friendly software module to help the users:
 In selection of proper quality of nonwoven/functional fabrics for specific
end use applications
 To avoid unnecessary wastage of time and materials, which otherwise
would be due to wrong selection of materials for any specific application
 Mainly dealing with the development of functional textiles having very
high growth potential during the days to come

Conclusion:
• Designed & developed prototype device for monitoring the quality of
nonwoven/functional textiles.
• Prepared algorithm for development of software module most suitable for
different varieties of fabrics.
• Tested nonwoven fabrics for different quality parameters and validate the results
so obtained by capturing multiple images of same fabric samples using image
processing technique. The results show the variability of the order of only 5-10
% which is considered to be negligible.

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 • Tested other functional fabrics for different quality parameters and validate the
results so obtained by capturing multiple images of same fabric samples using
image processing technique. The results show the variability of the order of only
5-12 % which is considered to be negligible.

Copies of papers published and a list of all publications arising from the thesis:
INTERNATIONAL:
1. ―Industrial Fabrics used in Conveyor & Power Transmission Belts‖ – paper
published in the Proceedings of 6th International Conference on ―Advances in
Textiles, Machinery, Nonwovens and Technical Textiles‖ held during 7th -9th of
December 2009 at Bannari Amman Institute of Tech., Sathyamangalam, Erode
District, Tamilnadu, India , organized jointly with Texas Tech University,
Nonwovens & Advanced Materials Laboratory, The Institute of Environmental &
Human Health, Lubbock, USA
2. ―Quality Parameters for Medical Textiles and Their Assessment‖ - paper published
in the Proceedings of MEDITEX-2014 International Conference on ―Current Trends
in Medical Textile Research‖ organized by Centre of Excellence In Medical
Textiles, The South India Textile Research Association, Coimbatore, Tamil Nadu,
India and sponsored by Office of the Textile Commissioner, Ministry of Textiles,
Government of India on 1st March, 2014.
3. ―Quality Parameters for Baby Diapers and Their Assessment‖ - paper published in
the Proceedings of INDO – CZECH INTERNATIONAL CONFERENCE on
―Advancements in Specialty Textiles and their Applications in Material Engineering
and Medical Sciences (ICIC 2014) ‖ organized jointly by Department of Textile
Technology / Department of Fashion Technology, Kumaraguru College of
Technology, Coimbatore and Technical University of Liberec, Faculty of Textile
Engineering, Czech Republic during 29th-30th April, 2014.
4. ―Development of Eco Friendly and Cost Effective Solutions for Packaging
Industries‖- paper published in the Proceedings of International Conference on
―Technical Textiles and Nonwovens‖ organized by IIT Delhi during 6-8 November,
2014 at IIT Delhi.

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5. ―Development of Conductive Fabrics and their Applications in Textiles‖ – in
TEXTILE ASIA, p.29-32, Dec. 2011.
6. ―Developments in Medical Textiles for the Need of the Day‖- paper published as a
Poster at the International Conference on ―Technical Textiles and Nonwovens‖
organized by IIT Delhi during 6-8 November, 2014 at IIT Delhi.
7. ―Quality Requirements For Woven Fabrics Used As Functional Textiles‖, paper
published in the Proceedings of the Global Textile Congress organized by The
Textile Association (India) in association with Thailand Convention & Exhibition
Centre, Thailand Theme : ―Global Textile – Opportunities & Challenges in an
Integrated Word‖ during 13-15 February, 2015 at Ambassador Hotel (Convention
Hall ), Bangkok, Thailand.
8. ―High Performance Nonwovens for Infrastructural Developments in India‖ – paper
published in the Proceedings of the Second International Conference on Nonwovens
for High Performance Applications organized by the International Newsletters Ltd.,
UK during 4-5 March, 2015 at Novotel Hotel, Cannes, France.

NATIONAL:
9. ―Influence of Properties of Back-Up Fabrics on Properties of Synthetic Leather‖ in
Journal of the Textile Association. May-June, 2014, Vol. No. 75 No. 1 pg.39.
10. ―A Review of Detection of Structural Variability in Textiles using Image Processing
and Computer Vision‖ in Journal for Research| Volume 01| Issue 12 | February 2016
ISSN: 2395-7549, pg. 46-50

Patents: Filed Provisional patent with Application No. TEMP/E-1/11942/2016-MUM.

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