You are on page 1of 5

Warping Calculation Prepared by: M.

Ahsan Mir

PRODUCTION
Production of a warping machine can be calculated as
Production = Speed (rpm) * 60 * Time (hrs)

Production capacity of a warping machine means production when it is run at maximum speed.
So

Production = 1200*60*24
=1728000 m

Quality of yarn: the quality of yarn is checked by two methods


1. weight method
2. length method
1. Weight method
Following is the formula to calculate the weight of warp
Weight warp (lbs) = Length (yards) * Total Ends
840* Count
So to check the quality weight wise, there is a specific term used for it which is known as
pounds/break (lbs/break)
Lbs/break = Length (yards) * Ends
840* Count*no. of breaks
If value of lbs/break is high, than quality of yarn is good. If its low than more the b grade yarn
will be.
2. Length method
In length method, no. of brakes in 10 million meters is calculated
Break/
10 million meters
Break/10 million meters = 107*no of breaks
Length (m)* Ends
If breaks /10 million meters is low, than higher will be the quality of yarn and if its value is high
than yarn will be of low quality.
Warping Calculation Prepared by: M.Ahsan Mir

16s Cotton 21s Cotton


Brand Brake/10 Lbs/break Brand Brake/ Lbs/brake
Mm 10mm
Sun Raiz 9.30 84 Marral 6.69 93
Dawood 7.08 115 Crescent Jute 7.71 80
Mehmod 9.02 90 Best 5.25 116
Mas.
Asim 10.32 79 Altex 4.51 135
Reliance 7.69 106 Colony 8.45 73
Asim 10.20 80 Mehran 8.04 77
Riaz 6.87 118 Marral 5.02 103
2
40 Cotton
Brand Brake/10 Lbs/brak
Mm
Umer 10.01 65
Din 12.10 54
Umer 6.47 101
Superior 16.28 40
Umer 8.12 80
Fazal cloth 13.70 48
Kunjah 24.34 27

Standards for these counts in Sapphire Diamond weaving unit is as follow


16/1 = brakes/10MM less than 8, Lbs/ Brake more than 116
21/1 = brakes/10MM less than 5.5, Lbs/ Brake more than 118
40/2 = brakes/10MM less than 6, Lbs/ Brake more than 108
Warping Calculation Prepared by: M.Ahsan Mir

SET CALCULATIONS
While performing set calculations while factors have to be considered
-Quality - Total ends
- No. of creels - Cone weight
- Cone length - Total no. of bags
- Set length - Creel Capacity

Creel capacity 1170


Machine Benniger
Count 60
Cone weight 4.167 lbs

Quality 60 X 60 X 110
180 X 106

Total ends = ends / inch x width = 19800

No of beams = Total ends


Creel capacity
= 19800
1170
= 16.92 = 17

Ends/ beams = Total ends / No. of beams = 19800


17
= 1164.7059 = 1165 x 12= 13980, 1164 x 5= 5820
= 13980 + 5820 = 19800
Warping Calculation Prepared by: M.Ahsan Mir

Cone length = Cone weight (lbs.) X 768.1 X count


= 4.167 X 768.1 X 60
= 192040 m

We will take 2% cone remainder length taken = 190119 m

We take set length by dividing length taken to the total no of beams

Set length = cone length/ beam


= 190119 m/17 = 11183.47 = 11183 mtrs
Either we have no. of creels or total no. of bags
We have 3 creels

No of bags = Total ends X no of creels


No of beams X cones/ bag

= 19800 X 3
17 X 24
= 145.588bags = .588 x 24 = 14.112
= 145 bags and 14 cones.

BEAM LENGTH CALCULATIONS


Ends/ beam = 1165
Count = 60
Density = 0.5 gm/cm*3
Dia of flange = D = 1000mm = 100 cm
Dia of barrel = d = 307mm = 30.7 cm
Width of beam = W = 2400mm = 240 cm
Volume = 3.147 [D*2 - d*2] X W
4
Warping Calculation Prepared by: M.Ahsan Mir

= 3.147 [ (100)*2 - (30.7)*2 ] X 240


4
= 1707300 cm*3
Mass = Volume X Density
= 1707300 X 0.5
= 853650.2 gm
= 1881.94 lbs

Weight (lbs) = Total length X Total ends/beam


768.1 X count
Total length = 1881.94 X 768.1 X 60
953
= 91104.0824 m
= 91104 m

Formula used in mill to calculate length of yarn on beam


Dia of flange = D = 1000 mm
Dia of Barrel = d = 21 mm
Length of yarn on beam = ((D*2-d*2) x 1.585 x Count of yarn)
Reed count x reed filling

You might also like