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Published on Aug 2, 2014

Production = no. of needle x no of feeder x RPM x stitch ...

length/ yarn count %
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' Textile Calculations and Equations

1. TEXTILE CALCULATION & EQUATION
2. Name : MAZADUL HASAN SHESHIR ID: 2010000400008
Batch: 13th Batch (Session 2009-2013) Department: Wet
Processing Technology Email: mazadulhasan@yahoo.com Blog:
www. Textilelab.blogspot.com Southeast University Department
of Textile Engineering PREPARED BY ©right
3. Spinning Calculation and Equation
4. Basic Conversions (Spinning) No Length Weight Time 1. 1 in
= 2.54 cm 1 lb = 7000 gr 1 min = 60 sec 2. 1 yd = 36 in 1 lb =
16 oz 1 hr = 60 min 3. 1 m = 1.0936 yd 1 oz = 437.5 gr 1 shift
= 8 hr 4. 1 Hk = 840 yd 1 kg = 2.2046 lb 1 day = 24 hr 5. 1 Hk
= 7 leas 1 bag = 100 lb 1 day = 3 shifts
5. Count Conversion Table (Spinning) Ne Nm Tex Grex Denier
Ne= 1 xNe 0.5905 xNm 590.5 /Tex 5905 /Grex 5315 /Den
Nm= 1.693xNe 1 xNm 1000 /Tex 10,000/Grex 9000 /Den Tex=
590.5 /Ne 1000 /Nm 1 xTex 0.1 xGrex 0.111 xDen Grex= 5905
/Ne 10,000 /Nm 10 xTex 1 xGrex 1.111 xDen Denier= 5315
/Ne 9000 /Nm 9 xTex 0.9 xGrex 1 xDen
6. Draft & TPI Formulas
7. Efficiency Percentage (Spinning) Cleaning Efficiency (%)
Efficiency (%) Twists per inch
8. PRODUCTION CALCULATION FORMULAS
9. PRODUCTION FORMULAS
10. Yarn Count in Direct system System Unit weight Unit length
Uses Tex Grams 1,000m Polyester Denier Grams 9,000m Lycra
D-Tex Grams 10,000m Lycra Pounds/Spyndle Pounds
14400yds Jute Yarn Count in Indirect system System Unit
weight Unit length Uses English (Ne) 1 lb 840 yds Cotton yarn
Metric (Nm) 1 kg 1 km Cotton yarn Worsted 1 lb 560 yds
Worsted yarn Woolen 1 lb 256 yds Woolen yarn
11. Excellence of fiber quality by combing:
12. Fabric (Knitting & Weaving) Calculation and Equation
13. SIZING
14. Calculation:
15. Required Chemical &no. of Mixing of Sizing Recipe:
16. Production is calculated in accordance with the following
equation-
17. Production calculation: 1. Production = no. of needle x no
of feeder x RPM x stitch length/ yarn count Production per shift
in KG at 100% efficiency Where, Ks = knitting constant Count =
linear density of yarn GSM = gm per square meter Another
formulae is : Stitch length = (Tex × Ks) / GSM Ks is a constant.
Its value is different for different fabric structure and fabric type.
Ks is calculated and estimated as below: Ks = (GSM x Stitch
length) / Tex
18. Production calculation: Fabric type Color Value of Ks Single
jersey Average 19.55 Single lacoste Average 22.4 Double
lacoste Average 22.75 Polo pique Average 25 Plain interlock
Average 39.3 1 X 1 rib Light 24.5 1 X 1 rib Average 26.5 Ks =
(GSM x Stitch length) / Tex
19. Relation between yarn count and m/c gauge seen in
different m/c.:
20. GSM Calculation
21. DIFFERENT FABRIC GSM AND THEIR REQUIRED YARN
COUNT S/J without lycra - Fabric G.S.M Yarn Count 110 - 120
40 S – 36 S 120 - 130 36 S - 32 S 130 - 140 32 S – 28 S 140 -
150 28 S 150 - 160 26 S 170 - 210 24 S Rib without lycra -
Fabric G.S.M Yarn Count 180 - 190 36 S - 32 S 190 - 200 30 S
200 - 215 28 S 215 - 230 26 S 230 - 250 24 S 250 - 300 24 S
22. Interlock without lycra - Fabric G.S.M Yarn Count 200 - 220
34 S 220 - 230 32 S 230 - 250 30 S 250 - 300 26 S Lacoste
without lycra - Fabric G.S.M Yarn Count 180 - 190 30 S 190 -
210 28 S 210 - 230 26 S 230 – 250 26 S 40D Lycra Rib -
Fabric G.S.M Yarn Count 230 - 240 32 S 240 - 250 30 S 250 -
280 26 S 280 - 300 24 S 40D Lycra S/J – Fabric G.S.M Yarn
Count 180 - 190 34 S 190 - 210 32 S 210 - 220 30 S 220 –
240 28 S 240 - 250 26 S DIFFERENT FABRIC GSM AND
THEIR REQUIRED YARN COUNT
23. Yarn Dyeing Calculation and Equation
24. Production Calculation of Yarn singeing machine: Length =
Count * Weight = Count * Weight * 840 yards = (Count * Weight
* 840) / rpm yards per minute = (Count * Weight * 840) / rpm *
60 * 8 * 3 yards per day = (Count * Weight * 840) / rpm * 60 * 8
* 3 * 0.914 =……X…meter/day.
25. Production Calculation of reeling machine:
26. Production Calculation of hank to cone winding machine:
Machine Parameter Yarn quality Speed (rpm) 58/2, 60/2 450 All
single count 500 to 550 Length = Count Weight = Count *
Weight 840 yards = (Count Weight 840) / rpm yards per
minute = (Count Weight 840) / rpm 60 8 3 yards per
day = (Count Weight 840) / rpm 60 8 3 0.914 =……
X…meter/day.
27. GSM Calculation: WPI = 32 CPI = 45 Stitch length = 3 mm
Yarn Count = 20’S Ne
28. No. of Needle = π × Machine Diameter (D) × Machine
Gauge (N) = 3.1416 × 30 × 24 = 2262 Yarn Count = 30/1 Ne
No. of Feeder = 96 Machine RPM = 28 Stitch length = 3 mm
Efficiency = 85% = 0.85 Shift = 8 hr. = 8 × 60 = 480 min
Production Calculation Of Yarn Dyeing Machine : Production of
the machine is 146.407 Kg/Shift. Note: If any parameter in this
calculation is changed then production capacity per shift will be
changed.
29. Package Density Calculation (Yarn Dyeing): Formula
30. Density Calculation for Several Counts (Yarn dyeing):
1**Before Pressing • Yarn Quality: 30/1 cc • Package Height
(H) = 162mm = 16.2cm • Total Package Dia (D1) = 162mm =
16.2cm • Total Package Weight (W1) = 1.38kg = 1380gm •
Spring Weight (W2) = 0.185kg = 185gm • Spring Dia (D2) = 65
mm = 6.5cm
31. 2 **After Pressing Yarn Quality: 30/1 cc Package Height (H)
= 145mm = 14.5cm Total Package Dia (D1) = 165mm =
16.5cm Total Package Weight (W1) = 1.38kg = 1380gm Spring
Weight (W2) = 0.185kg = 185gm Spring Dia (D2) = 65 mm =
6.5cm **So we can sure that after pressing for every count,
yarn package density will be increase. Density Calculation for
Several Counts (Yarn dyeing):
32. Length Calculation in Package: To maintain the constant
package density same length of yarn should be wound to all
the packages of a batch or lot. The dyeing machine capacity is
calculated on weight, so it is necessary to maintain the uniform
weight throughout the packages. To do this for a definite count
of yarn following calculation is followed, In this machine length
is pre selected. For different count of yarn different length of
yarn is pre selected. This is due to maintain the constant
package weight and package density.
33. Package density Calculation We know package density ρ
=mass (m)/volume (v) gm/cc Volume= π (R2-r 2) h R= outer
radius of package R= inner radius of package h= height of
package Now we consider a sample of 40/1 cotton yarn whose
R=4.138 r= 1.59 h=15.24 Mass m=1000gm So package
density ρ=1000/π (4.1382-1.592)15.24 gm/cc =1.433 gm/cc
Production calculation: We know production= speed (m/min)
×60×24 ×1.09/(840×40×2.2045) Kg/day/head When speed is
800m/min at 80% efficiency Production=800×60×24×1.09/
(840×40×2.2045)kg/day/head =10.5976kg/day/head Total
production=10.5976×54×12kg/day =6867.2448kg/day
34. Production calculation of RF Dryer : Length of RF Dryer =
13m At 28rpm it takes 21 min 9 sec to pass this length Along
this length it can accommodate 416 package 416kgs So at 21
min9sec or 1269sec it can dry 416kgs So in 1hr or 3600sec it
can dry = 416×3600/1269 kg/hr = 1180.14 kg/hr So
Production per day = 1180.14×24kg = 22658.688 kg = 22.66
tons Production calculation of RF Dryer
35. Knit Dyeing Calculation and Equation
36. Calculations related to batch section: Now, when a gram
per linear meter is low then meters per chamber will be more.
Thus, fabric loading should be reduced to avoid jamming in the
winch. In this case 80-85% fabric loading is given. But when
gram per linear meter is more then rope length will reduce and
in this case up to 90% fabric loading can be given.
37. Calculating the chamber loading In the following table are
listed general recommendations covering rope cycle times and
speeds for a wide range of fabrics: Fabric Rope cycle times in
minutes (Cycle Time) Rope circulation speed m/min (Reel
speed) Knit fabric PES unfixed 1 250 PES heat set 1-1.5 200
PC 1-2 250 Co - reactive 2-3 225-275
38. Preparation and storage of stock dyes and chemicals
Available stock solution: 1. Red-0.1%, 0.5%, 1%, 2% 2. Yellow-
0.1%, 0.5%, 1.0%, 2.0%, 3. Blue- 0.1%, 0.5%, 1.0%, 2.0%.
Preparation: To prepare 0.1% stock solution, it necessary to
mix 0.1 gm dye with 100cc water. To prepare 0.5% stock
solution, it necessary to mix 0.5 gm dye with 100cc water. To
prepare 1.0% & 2.0% stock solution similar procedure is
followed. To prepare 10% stock solution of soda ash, it
necessary to mix 10 gm soda with 100cc water. SHADE %
STOCK SOLUTION % 0.0001-0.009 0.1 0.10-0.99 0.5 1-1.99
1 2-3.99 2 4 ( or above) 4 Stock solution preparation:
39. Stock Solution Making Procedure (Dyeing lab) For solid, X
gm chemicals/dyes/auxiliaries in the 100 ml water is called x%
stock solution. For liquid, X ml/cc chemicals/dyes/auxiliaries in
the (100 - x ml/cc) water is called x% stock solution.
Conversion formula from percentage to g/l is as g/l = Required
amount (%)× 10
40. Recipe Calculation
41. Dyes and chemicals measuring formula for laboratory: The
amount of dye solution (ml) is calculated as follow – The
amount of chemical soln (ml) is measured as follow –
42. Fabric Type GSM Pump Speed % Reel Speed(MPM) Single
Jersey Up to 140 80 250 140 – 180 85 230 180 – above 90
210 Polo Pique, Back Pique & Bubble Knit Up to 160 85 280
160 – 200 90 260 220 – above 90 240 Interlock Up to 180 85
260 180 – 220 90 240 220 – above 90 220 Machine Setup On
The Basis Of Fabric Type & GSM
43. MONTHLY EFFICIENCY OF KNITTING FLOOR: Daily
production – 6500 kgs. Approx. Daily production capacity –
10000 kgs approx. So, monthly production – 6500 x 30 kgs.
Monthly production capacity – 10000 x 30 kgs. So, Monthly
production efficiency = (6500x30x100)/ (10000x30) % = 65%
44. Garments Calculation and Equation
45. COSTING OF THE PRODUCT: Let price of yarn is $ 3.00/
kg. Process loss of yarn for knitting (10%) = $0.30 Knitting
fabric cost = $3.30 Cost of dyes & chemicals = $2.50 Process
loss for dyeing (12%) = $0.30 Dyed fabric cost = $ 6.10
Packing cost = $0.05 Production cost of fabric=$6.15 Fabric
price (with 25% margin) =$7.79 Fabric consumption/ doz. =
(Body length + Sleeve length +10) x Chest length x 2 x GSM
x12 /10000000
46. Garments specification: Body length=78 cm Sleeve
length=33 cm Chest length=62 cm GSM=210 Fabric
consumption/ doz. = {(78+33) x62x2x210x12}/ 10000000 =
3.469 kg Fabric consumption/doze (with 10% wastage) =
3.816 kg Body fabric cost / doz. =$(7.79x 3.816) = $29.73
Cost of collar& cuff/doz = $ 4.00 Cost of Trims=$ 2.25 Cost of
Trims (with 5% Process loss) = $2.36 Production Cost of
Garments/ doz=$36.09 Garments Price/doz (with 25% Profit)
=$45.12 COSTING OF THE PRODUCT:
47. Costing of Men’s shirt Fabric consumption for a dozen of
shirt π × L ═ size of basic shirt. Width of body of shirt ═ 1/2
chest ═ 24"+1"(sewing allowance) ═ 25" Body length ═ 32"+1"
(sewing allowance) ═ 33" Sleeve length ═ 23"+2.5(cost) +1.5"
(sewing allowance) ═ 27" Consumption of a body shirt: ═{1/2
chest× (body length) ×2} / 36× fabric width. (Sq. inch)
═25"×33"×2 (Sq. inch ). {Let assume fabric width 25"effective
width ═25"−1" ═ 24"} Fabric length ═25×33×2 / 44 inch
48. Fabric consumption ═25×33×2 / 44×36 yds Consumption
of sleeve ═ (length of sleeve × width sleeve) ×2 sq. inch
═27"×24"×2" (Sq. inch) Fabric consumption in length width ═
27×24×2 / 44×36 sq. inch Total fabric consumption of one
dozen shirt ═ [(25×33×2 / 44×36 + / 27×24×2 / 44×36) ×2+
wastage of 8%] ═ 22.75 yds + 8% wastage ═24.6 yds Sewing
threads consumption: It is calculated by measuring the total of
different kind of seam. Normally sewing threads consumption
per shirt , 120m. So, sewing threads consumption per dozen, ═
120 × 12 ═ 1440m Costing of Men’s shirt
49. Costing of T- shirt Fabric Type :Single jersey G.S.M :180
Yarn count :24/1 Measurement of Garments: Body length : 54
cm Chest length : 43 cm Sleeve length : 15 cm Fabric
Consumption = {(Body length + sleeve length + allowance) *
(Chest length + 3)} * 2 /10,000 * G.S.M / 1000 * 12 * 10 % (+) =
{( 54 + 15 + 10 ) * ( 43 + 3 )} * 2 / 10,000 * 180 / 1000 * 12 *
10% (+) =1.72 kg =1.72* 0.18 = 1.90 kg / doz. Costing Fabrics
cost : 17.10 Cost of making : 4.5 Print cost : 3.5 Lab cost :
0.20 Accessories cost : 2.5 Washing cost : 1 Total = $ 28.80 /
Doz. = $ 2.40 / pcs.
50. How can we get Fabric Consumption & Fabrics Price? Say:
** Body Length = 85, Chest Width = 52, Sleeve Length = 44 &
G.S.M = 240 Fabric Description: 100 % Cotton S/J Fabric
Need = [(85+5+44+5) 52+5] 2 12 240/10000000+10%
= [(90+49) 57] 2 12 240/10000000+10% = (139 57) 2
12 240/10000000+10% = 7923 12 240/10000000+10%
= 45636480/10000000 + 10% = 4.563648 +10% = 4.563648
+ .4563 = 5.02 Kgs Fabrics Say Per Kgs Price: US$ 6.00/Kgs
51. Poly bag costing : Total Length X width X Thickness =
36cm X 28cm X 10mm = 10080/72000 = 0.14pcs/lb Fabrics
Price: Total Fabric Need 5.00 Kg $ 6.00 = $ 30.00 Trim/
Accessories (Minimum Charge) = $ 2.50 Cutting & Making
Charge (C.M) = $ 5.00 Printing Charge (If any) = $ 0.00
Embroidery Charge (If any) = $ 0.00 Buying Commission (If
necessary) 5% = $ 1.97 Final/Total = $ 39.47/12 Costing of a
garment: Fabric cost + Accessories cost + Trimming cost +
Production cost + Transport cost + Commission + Profit
52. Consumption of T-Shirt: Equation: {(Body length + Sleeve
length) Chest} 2 GSM 10000 1000 5000 Solution:
Body Length = 50 + 6 (Allowance) = 56 cm Sleeve Length = 15
+ 3 (Allowance) = 18 cm Chest = 37 + 3 (Allowance) = 40 cm
GSM = 180 cm = {(56 + 18) 40} 2 180 10000 1000
5000 = 532.8 kg.
53. Consumption of Collar: Equation: {(Neck width + Front neck
drop) collar depth} 2 GSM 10000 1000 5000
Solution: Neck width =22 2 = 44 cm Front neck drop =5 cm
Collar depth =2.5 cm 2 = 5 cm GSM = 240 = {(44 + 5) 5}
2 140 10000 1000 5000 = 58.8 kg. Total = 532.8 +
58.8 kg = 591 kg
54. Collar & Cuff measurements Size Collar measurement (cm)
Cuff measurement (cm) S 40 x 9 40 x 3.5 M 42 x 9 40 x 3.5 L
44 x 9 40 x 3.5 XL 46 x 9 40 x 3.5 XXL 48 x 9 44 x 3.5 XXXL 50
x 9 44 x 3.5
55. Consumption of bottom part: Equation: Length*
(width*4)*G.S.M÷10000÷1000*12 Length=53=8=2=63cm
Width= 18*4+6= 78cm G.S.M= 260 Solution
[(63*78*260)÷10000÷1000*12 =1.53kgs
56. Consumption of Pocket: Equation:
Length*width*G.S.M÷10000÷1000*12 Length=11+2=13cm
Width=10cm G.S.M= 260 Solution (13*10)
*260÷10000÷1000*12 =0.04056kg Total= 1.53+0.04056
1.5705kg
57. Costing process: Finish fabric cost: (Yarn price + Knitting
cost + dyeing cost) Body fabric cost: (Total fabric consumption
+ Total yarn consumption) Cost of making
(CM):……………………………$ Accessories
cost:…………………………………..$ Overhead
cost………………………………………$ Others
cost:………………………………………….$ Buyer
commission:……………………………….$ Total
cost..................................................$ Costing process: PRICE
OF THE PRODUCT: Generally price of product is determined by
the required profit adding to the total expenses. So, Price of
products = (Direct expenses + Indirect expenses + Factory
Overhead) + Required profit
58. MARKER EFFICIENCY: The marker planner measures his
success by the efficiency of the marker plan. The following
formula is used to measure the efficiency: Marker
efficiency=Area of the pattern in the marker plan/ Total area of
the marker plan X 100%. MARKER EFFICIENCY:
59. STANDARD TIME = Normal time + Allowances = Normal
time + (Normal time ×Allowances) = NT (1+ Allowances). In
garments production world, the terms SMV or SAM used
frequently. SMV stands for Standard Minute Value. SAM for
Standard allocated minute or Standard Allowed Minute. SMV
CALCULATION: SMV calculation of a basic T-shirt from a time
study sheet of a garments industry. Following formulas are use-
Normal time = (Average observed time) × (Performance rating
factor). SMV (Standard Minute Value) = Basic Time +
(Allowances × Basic time). = Basic Time× (1+ Allowance).
Allowances are assumed for this calculation is 20%. SMV
60. SMV Target Production /Hour = (No Of worker -1) x 60 /
SMV SMV= standard Mean Value (the Time Required to
Complete garments by sewing ) SMV=( Basic time +Allowance )
61. To select sewing thread, thread size or number is very
important. The number which is used to express the fineness of
a sewing thread is called sewing thread number or ticket
number. It has 2 system as follows- Cotton system : It is
derived from English cotton system. Cotton ticket number in Ne
= ( Yarn count in Ne / Number of ply ) x 3 Metric system : It is
derived from Metric count system. Ticket number in Nm = (
Yarn count in Nm / Number of ply ) x 3 sewing thread number
or ticket number
62. Equation For Find Yarn Count (If GSM is Known) Single
Jersey = 4300 /GSM Pique = 5200 / GSM Fleece = 7200 /
GSM Interlock = 7200 / GSM 1x1 rib = 6000 / GSM
Locoest =5500 / GSM 2x2 rib = 6250 / GSM Terry = 6240 /
GSM
63. Find out Required Yarn Count (If GSM is Known) Equation :
S/j Ne = (0.141x GSM) + 50.22 Pique Ne = (0.146x GSM) +
57.16 Double Lacost Ne = (0.167 X GSM) + 64.36 1X1 Rib Ne
= (0.123X GSM) + 54.57 Interlock = (0.206X GSM) + 80.56
Lycra 1X1 Rib = (0.119 X GSM) + 59.12 Lycra 2X2 Rib =
(0.108X GSM) + 56.62
64. Conversion of (GSM Equation ) Kg To Yards Equation : =
GSM / 39.37 X 36 X fabric Width =Result .Kg =1000/ Result
.yds [It is converted Kg To yards ] Per Yards Fabric price
Equation : = GSM / 43” X Width / 1000 X Per kg Prize =Result .
[This the Equation define per yards Fabric price ]
65. Conversion of (GSM Equation ) Yards To meter Equation : =
Length X 36 X 2.54 /1000 =Result [It is converted yards to
Meter ] Meter To Yards Equation : = Length /36 / 2.54 X 1000
=Result [ It is converted Meter To yards ]
66. Conversion of (GSM Equation ) Find Out How many Yds /
Kg Equation : = 714//GSM =Result (yds in Kg) [Only For
58’’/60’’ Width] Price/Yards Equation : = GSM /43 / 2.54 X
Width =Result / 1000 X Price = price/yds
67. Textile Testing Calculation and Equation
68. Four point grading system Size of defects Penalty 3 inches
or less 1 point Over 3 inch but not over 6 inch 2 point Over 6
inch but not over 9 inch 3 point Over 9 inch 4 point Four point
grading system
69. Shrinkage Test:
70. Spirality test:

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