Production of Knitted Fabric

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Yarn requirement

 Generally, in knitting, the required fabric order is placed weight

wise. The equal amount of yarn in weight are required to
produce the fabric. In case of fabric produced with single type
of yarn like Single jersey, Rib, interlock and most of their
derivatives, required yarn weight will be:
 Yarn required = Required fabric weight (1 + Wastage %)
 The wastages during knitted fabric production vary from unit to
unit, and normally range from 2-5%.
3 Terry fabrics (two end and three end)
 When the fabric is produced from two or more different kinds of yarns, then we
need to calculate the percentage of each yarn in the fabric. The requirement of
each yarn will be according to the percentage of the total required weight of
the fabric.
 In case of 2 end terry fabric, the fabric is composed of two different yarn, one is
a knit yarn and other is pile or loop yarn. The requirement of each yarn can be
calculated as follows.
𝐾𝑌𝑟 = 𝐾𝑌%× 𝐹𝑤
𝑇𝐾𝑌𝑟 = 𝐾𝑌𝑟×( 1+𝑊%)
𝐿𝑌𝑟 = 𝐿𝑌%× 𝐹𝑤
𝑇𝐿𝑌𝑟 = 𝐿𝑌𝑟×( 1+𝑊%)
Where: 𝐾𝑌𝑟=𝐾𝑛𝑖𝑡 𝑦𝑎𝑟𝑛 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡, 𝐾𝑌%= 𝐾𝑛𝑖𝑡 𝑦𝑎𝑟𝑛 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒
𝐹𝑤=𝐹𝑎𝑏𝑟𝑖𝑐 𝑊𝑒𝑖𝑔ℎ𝑡 𝑇𝐾𝑌𝑟=𝑇𝑜𝑡𝑎𝑙 𝑘𝑛𝑖𝑡 𝑦𝑎𝑟𝑛 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 𝑊%=𝑊𝑎𝑠𝑡𝑎𝑔𝑒 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒
𝐿𝑌𝑟=𝐿𝑜𝑜𝑝 𝑦𝑎𝑟𝑛 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 𝐿𝑌%= 𝐿𝑜𝑜𝑝 𝑦𝑎𝑟𝑛 𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒, 𝐿𝐾𝑌𝑟=𝑇𝑜𝑡𝑎𝑙 𝑙𝑜𝑜𝑝 𝑦𝑎𝑟𝑛
𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡
 Example:
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It is required to produce 2000 kg of a terry fabric composed of three thread used at
different knitting position (knit, binding and loop). The percentage of yarn at different
position is 50, 35 and 15 respectively. Calculate the yarn requirement for each
position with additional percentage of 2 %.
Solution:
 There are three different yarn used at different knitting position in 3 thread fabric.
 To calculate the yarn requirement for each yarn. We have the following relation.
𝐾𝑌𝑟 = 𝐾𝑌%× 𝐹𝑤= 50/100 ×2000=1000 𝑘𝑔𝑠
𝑇𝐾𝑌𝑟 = 𝐾𝑌𝑟+ 𝑊%×𝐾𝑌𝑟= 1000 +(2/100× 1000) = 1020 Kgs
𝐵𝑌𝑟 = 𝐵𝑌%× 𝐹𝑤=35/100× 2000=700 𝐾𝑔𝑠
𝑇𝐵𝑌𝑟 = 𝐵𝑌𝑟+ 𝑊%×𝐵𝑌𝑟= 700 +(2/100 × 700) = 714 𝐾𝑔𝑠
𝐿𝑌𝑟 = 𝐿𝑌%× 𝐹𝑤=15/100 × 2000 = 300 𝐾𝑔𝑠
𝑇𝐿𝑌𝑟 = 𝐿𝑌𝑟+ 𝑊%×𝐿𝑌𝑟= 300 +(2/100 × 300) = 306 𝐾𝑔𝑠
 Production of Circular knitting Machine
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 The Production of the circular knitting machine is commonly
expressed in terms of length (yards, meters) and weight (Kgs,
Lbs.) in specific times.

 It depends on a number of factors; mainly

 machine speed,
 number of feeders,
 fabric parameters, etc.
 Production of Circular knitting Machine
6  The production of circular knitting machine in Yards/hour can be
determined from the following formula.
𝑠 𝑥 𝑓 𝑥 𝑡 𝑥 60 𝑥 𝐹
𝑃 𝑦𝑑𝑠.Τ𝑡 = 𝑥 𝐸%
𝐶𝑃𝐼 𝑥 36
𝑠 𝑥 𝑓 𝑥 60 𝑥 𝐹
𝑃 𝑚𝑡𝑟𝑠.Τ𝑡 = 𝑥 𝐸%
𝐶𝑃𝐼 𝑥 39.36
Where,
𝑃 = 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛
𝑡 = 𝑡𝑖𝑚𝑒 (ℎ𝑜𝑢𝑟𝑠)
𝑠 = 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝑠𝑝𝑒𝑒𝑑 (𝑅𝑃𝑀)
𝑓 = 𝑁𝑜 𝑜𝑓 𝑓𝑒𝑒𝑑𝑒𝑟𝑠
𝐹 = 𝑓𝑎𝑏𝑟𝑖𝑐 𝑙𝑒𝑛𝑔𝑡ℎ
𝐶𝑃𝐼 = 𝐶𝑜𝑢𝑟𝑠𝑒𝑠 𝑝𝑒𝑟 𝑖𝑛𝑐ℎ
𝐸% = 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒
 Production of Circular knitting Machine
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 The fabric production in weight per unit time can be calculated
from the following formula

𝑠 𝑥 𝑓 𝑥 𝑡 𝑥 𝑁 𝑥 𝑙 𝑥 60 𝑥 𝐹 𝑥 𝐶
𝑃 𝑙𝑏𝑠Τ𝑡 = 𝑥 𝐸%
2.54 𝑥 36 𝑥 840 𝑥 𝑁𝑒

Where
𝑁 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑛𝑒𝑒𝑑𝑙𝑒𝑠
𝑙 = 𝑆𝑡𝑖𝑡𝑐ℎ 𝑙𝑒𝑛𝑔𝑡ℎ (𝑐𝑚)
𝐶 = 𝑓𝑎𝑏𝑟𝑖𝑐 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡
𝑁𝑒 = 𝐸𝑛𝑔𝑙𝑖𝑠ℎ 𝑐𝑜𝑢𝑛𝑡
 Production of Circular knitting Machine
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𝑁 𝑥 𝑙 𝑥 𝐶𝑃𝐼 𝑥 36
𝐹𝑎𝑏𝑟𝑖𝑐 𝑤𝑒𝑖𝑔ℎ𝑡(𝑙𝑏𝑠) / 𝑙𝑖𝑛𝑒𝑎𝑟 𝑦𝑎𝑟𝑑𝑠 =
2.54 𝑥 36 𝑥 840 𝑥 𝑁𝑒

𝑁 𝑥 𝑙 𝑥 𝐶𝑃𝐼 𝑥 39.36
𝐹𝑎𝑏𝑟𝑖𝑐 𝑤𝑒𝑖𝑔ℎ𝑡(𝑙𝑏𝑠) / 𝑙𝑖𝑛𝑒𝑎𝑟 𝑚𝑒𝑡𝑒𝑟𝑠 =
2.54 𝑥 36 𝑥 840 𝑥 𝑁𝑒
 Example
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 Example
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11  Problem 3: A Calculate the production in pound per hour and yards per shift if the fabric is knitted on
a single knit machine with following parameters, efficiency of the machine is 84% (Consider shift =
12h)
 Number of Feeders = 20,
 RPM = 25
 S.L.= 0.38 cm
 No of needle =756
 CPI= 24
 Yarn Count=18/1
 Warp knitting Machine
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 Warp knitting may be defined as the loop
formation process along the warp direction
of the fabric.
 The simultaneous sheet of yarn is provided to
machine along the warp direction for loop
formation process.
 The sheets of yarn are supplied from warp
beam like in weaving. Each warp end is
provided to the each individual needle.
 The same yarn runs along the warp direction
and needle draws the new loop yarn
through the old loop that was formed by
another yarn in previous knitting cycle.
 Production of Warp knitting Machine
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 The production of warp knitted fabric can be calculated length
and weight wise over specific time.
 The following formula can be used to calculate the warp
knitting machine production
 Production of Warp knitting Machine
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 Example
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 Example
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