CREASE MARKS IN
W O V E N FA B R I C S
(CAUSES & SOLUTIONS)
P R E S E N TAT I O N B Y,
ALI ZAIN
DEPUTY MANAGER (WEAVING QUALITY)
DIAMOND FABRICS LIMITED, SAPPHIRE
W H AT A R E C R E A S E M A R K S ?
Crease Marks are unwanted permanent or temporary lines/folds that appear on fabric surfaces during weaving or handling. These
marks reduce aesthetic value, affect fabric performance (like during finishing), and increase rejections. Critical especially in export
denim, shirting, and greige fabric.
Crease mark in Greige Fabric Crease mark in Denim Fabric
TYPES OF CREASE MARKS
1. Permanent Crease Marks
Can't be removed even after finishing (e.g., hard set during weaving tension or roll pressing).
2. Temporary Crease Marks
May disappear after washing or finishing.
3. Mechanical Crease Marks
Caused by machine (loom) faults.
4. Handling Crease Marks
Caused during transport, inspection, or packing.
MAJOR CAUSES OF CREASE
M A R K S ( W E AV I N G S TA G E )
1. Improper Loom Tension Settings
Due to improper loom warp tension on weaver’s beam can cause crease marks in woven fabrics. Typically at the start of
the fabric roll formation when fabric is properly winded on the take-up roller. This type of creases appear at the end of the
inspection frame about 5 to 6 meters.
2. Woven Constructions with Lycra/Spandex Weft
Those woven fabric construction in which higher stretch in weft are more likely to have crease marks issues due to high
fabric shrinkage at loom stage.
For Example: If 20/1 CM CF COTT DUAL FX 50D T-400 + 105D LYCRA D-4.0 which is a high stretch yarn when used in
weft, then it will cause high shrinkage due to which there are high changes of crease marks if loom settings are not fined
tuned or uneven compressed air pressure in sub nozzles.
Solution: This can be avoided by using high width temples on loom and adjusting proper compressed air in sub
nozzles.
MAJOR CAUSES OF CREASE
M A R K S ( W E AV I N G S TA G E )
Crease Marks in Rigid Woven Construction Crease Marks in Stretch Woven Articles
MAJOR CAUSES OF CREASE
M A R K S ( W E AV I N G S TA G E )
3. Crease Mark due to Rolling Machine during Fabric Inspection
Sometimes during the fabric inspection stage when this fabric is winded again in roll form at the rolling machine, there are high
chances that the fabric may get Crease Marks due to tension imbalance, misalignment of Measuring Roller (Counter Roller or Pull
Roller) under the rolling machine which can create center creasing when fabric is not properly spread before reaching this roller.
Moreover, If the fabric passes at an angle or builds up on one side, the crease will become more visible. Too much winding speed of
Guide Roller can also cause Crease Marks on the fabric surface.
How To Prevent:
✓To prevent crease issue at rolling stage, Spreader Bar is used with the measuring roller or sometimes fabric is directly passed
through Spreader Bar instead of Measuring Roller to avoid crease issue.
✓Maintain uniform fabric tension during rolling.
✓Use edge sensors for auto alignment.
✓Keep rollers level and parallel.
MAJOR CAUSES OF CREASE
M A R K S ( W E AV I N G S TA G E )
C A U S E S F R O M P O S T W E AV I N G
HANDLING
4. Crease issue during Fabric Bale Formation
Sometimes during excessive pressure during bale packing of
fabric can cause cease marks in fabric.
5. Improper Handling
Due to improper handling and fabric transportation, creases may
appear on the fabric surface.
6. Improper Storage
Rolls that are stored under pressure or with folds can cause
creases on the fabric surface.
Fabric Bale Pressing
TROUBLESHOOTING CREASE
M A R K S ( F I N I S H I N G S TA G E )
1. Singeing Fabric at last step
Singeing burns off surface fibers if fabric has creases, the crease
fold lines don’t get evenly singed, resulting in uneven marks or
even permanent defects. By doing singeing at the end of the
process after the fabric has passed through Cold Pad Batch
(bleaching), mercerizing, stentering, and washing most of the
crease marks are relaxed or removed. This sequencing ensures
that the final singeing is smooth, uniform and free from any
distortion caused by earlier creases in the fabric.
OSTHOFF Singeing Machine
TROUBLESHOOTING CREASE
M A R K S ( F I N I S H I N G S TA G E )
2. Boaming (Caustic Soda Feed) Set Low (6–8 instead of 24–28) in Mercerizing Process
In normal mercerizing, boaming (caustic soda dosing) is kept high, typically between 24 to 28° Bé, to achieve full fiber swelling and
enhance the fabric’s luster and strength. However, when fabric contains crease marks, starting with a high boaming level can cause
those creases to become permanently set into the structure. To avoid this, the process begins with a reduced boaming level of 6 to 8°
Bé, allowing the fabric to swell gently and gradually open up, which helps release the crease lines. Once the fabric is relaxed and the
creases are minimized then we can pass fabric through CPB (Cold Pad Batcher), the boaming concentration is increased later in the
process to complete proper mercerization.
Benninger Mercerization Machine
TROUBLESHOOTING CREASE
M A R K S ( F I N I S H I N G S TA G E )
3. Chain Mercerization
In chain mercerization, the fabric is held flat and under controlled tension by clips or pins while passing through a caustic soda bath. The
swelling of cotton fibers in the alkaline environment helps open up and relax any crease lines formed earlier during weaving or batching.
As the fabric is uniformly stretched and then relaxed in the washing and neutralizing zones, the crease marks are effectively removed,
leaving a smooth and even surface ready for further finishing.
4. Wet Stretching
Wet stretching controls crease marks by taking advantage of the fabric’s flexible state when wet. During this stage, the fabric is
stretched under tension to relax folds, yarn puckers, and crease lines. The moisture softens the fiber structure, allowing distortions to be
corrected. Once stretched and dried, the fabric maintains a smooth and even surface, which significantly reduces or eliminates visible
creases.
RECOMMENDED FLOW CHART OF FINISHING
( TO E L I M I N AT E C R E A S E M A R K S )
Mercerization Hot Wash Heat Setting
(Low Boaming 6-8 (Stenter)
Be) (Pad Steam)
Cold Pad
CPB Dyeing Sanforization
Batcher CPB
Mercerization Hot Wash
(High Boaming 24- Singeing
28 Be) (Pad Steam)
Peaching
Heat Setting
(Mechanical
(Stenter)
Finish)
R O O T C A U S E A N A LY S I S ( R C A )
METHOD
Root Cause Analysis (RCA) is a systematic approach used to identify the underlying causes of problems or defects. In the context of
crease marks in woven fabrics, RCA helps uncover why these marks occur by breaking down contributing factors across different
categories such as machine, method, and manpower. Tools like the Fishbone Diagram (Ishikawa Diagram) are used to visually map
potential causes, enabling targeted corrective actions to eliminate the issue at its source and prevent recurrence.
Machine Method Man
Uneven Loom Tension
Incorrect Loom Settings Untrained Operators
Loose Fabric Winding
Skipping inspection Negligence
Noozle Malfunction
Crease Marks
Uneven Yarn Tension
Early High Boaming Improper Storage
High Loom RPM
Sudden Machine Stops Early Singeing Rough Handling
Fishbone Diagram (Ishikawa Diagram)