WEAVING CALCULATION & USEFUL
FORMULAS:
1. Count:
A number indicating the Mass per unit Length OR
The length per unit mass of Yarn.
Expression of the fineness of Yarn.
There are three Systems to Calculate Count -
1. Indirect System
2. Direct System
3. Universal System
1 Lea = 120 yd
7 Leas = 1 hank
1 Hank = 840 yds. or 768 meter
1. Indirect system
Total No. of hanks per one pound is the count of that yarn (Ne) i.e. if 10
hanks (10 x 840 yds. or 7680 meters) weighs one Pound or 0.454 Kg, then
the Count of Yarn in indirect system 10s or 10Ne.
This System widely used for staple fiber spun yarns like 100% Cotton,
Viscose, Polyester fibers and their blends.
Higher the yarn Count i.e. Ne the yarn is finer
2. Direct System
Count = Weight in grams per 9000 meters of yarn
In this system the yarn numbering is called as Denier (D)
Higher the yarn number i.e. Denier the yarn is coarser.
3. Universal System
Count = No of grams per 1000 meters or per km of yarn.
In this system count is called as Tex
Commonly used other numbering systems
I. Nf - French count: - It is the No of 1000 meters length in ½ kg of yarn
II. Nm - Metric system: - Count is the No of 1000 meters length per kg. of
yarn.
III. Worsted system: - Count is the No. of 560 yards in one lbs.
IV. Linen system: - It is the No. of leas of 300 yards per pound
V. Hemp, Jute, Flax: - Count is the No of 14,400 yards length per pound of
yarn
Conversion System
English (Ne) to Denier (D) - Denier = 5315 / Ne
English (Ne) to Tex - Tex = 590.5 / Ne
French (Nf) to English (Ne) - English (Ne) = Nf x 1.181
2. Twist per Inch or meter (TPI or TPM):
To give strength to the yarn, certain twist is given in the yarn.
TPI vary according to end use of yarn. More twist for warp yarns,
medium twist for weft yarns and less twist for hosiery yarns.
Twist is given in ‘Z’ direction or ‘S’ direction.
If twist is given in CW direction it is ‘Z’ twist.
If it is given in CCW direction it is ‘S’ twist.
Single yarns are given ‘Z’ twist and double yarns are given ‘S’ twist.
Twist relation for double yarn TPI = 0.7 x Single yarn TPI
3. Multi-filament Yarns
Multi-filament yarn are identified as 80/34/250, 80/34/0, 155/16/120
Here the first number denotes the Denier, second shows No. of filaments in
the yarn
& the last indicate No. of Twist per meter.
4. Winding Calculation
Slub – catcher settings:
a. Fixed Blade = Carded - (2.0 to 2.5) x Diameter
Combed - (1.5 to 2.0) x Diameter
b. Oscillating Blade = Smooth micro-set - 25% more than above
c. Serrated Blade = 100% more than the above
d. Electronic yarn clearer = 3 cm x 3 Diameter
5. Warping Calculations:
Production in meters. per 8 hrs.(K) = 480 x mtrs / min x E / 100 Kgs.
Production in Kgs. Per 8 hrs. = (K x N) / (1693 x English Count)
Warping Tension = 0.03 to 0.05 x Single Thread Strength
6. Sizing Calculations:
7. Weaving Calculations
Jute Carding:
In jute spinning, carding is the major area for jute yarn production process. In jute carding
machine the primary function of jute carding is done by the action of worker and cylinder and
the cleaning and the cleaning actions is done between worker and stripper. For jute yarn
production, some calculation formulas of jute carding are given below.
Jute Carding
Some important formulas for jute carding –
Surface speed (SS) of cylinder roller – SS of worker roller
1. Carding efficiency = ………………………………………………………………
Surface speed (SS) of cylinder
SS of cylinder
2. Carding Ratio = ……………………………
SS of worker
Dollop wt.
3. Wt. of feed sliver/100 yd = ……………………… X 100%
Clock length
Doubling
4. Wt. of delivery/100 yd = wt. of feed sliver/100yd X …………………..
Draft
Dollop wt. Doubling
= …………………… X 100 X …………………..
Clock length Draft
SS of delivery roller
5. Mechanical Draft = ……………………………
SS of feed roller
Calculated feed sliver wt. /100 yd
= ……………………………………………………………..
Calculated delivered sliver wt. /100 yd
Wt. /100 yd of feed material
6. Actual draft = ……………………………………….. X Doubling X Waste%
Wt. /100 yd of delivered material
= Mechanical draft X Waste%
7. Draft constant = DCP X Draft
8. SS of feed roller = π X Dia in inch X Speed
Length of feed material
= ……………………………………….
Doubling
SS of delivery roller
= ………………………………….
Draft
9. SS of delivery roller = π X Dia in inch X Speed
= SS of delivery roller X Lead%
10. Finisher card sliver wt. /100 yd
B/C sliver wt. /100 yd
= ………………………………………. X Doubling X Waste%
F/C draft
Dollop wt. B/C doubling F/C doubling
= …………………… X 100 X ………………… X ………………… X Waste%
Clock length B/C draft F/C draft
11. Production /hr = SS of delivery roller in inch /min X 60/36 X wt. of sliver/yd X Eff% X
Waste%
Dollop wt.
= SS of feed roller in inch/min X 60/36 X ……………………. X Eff% X Waste%
Clock length
Some Problems and Solutions:
1. The surface speed of cylinder is 2400 feet/min. If the carding efficiency 90%, then what
will be the SS of worker roller.
Solution:
SS of cylinder – SS of worker
Carding efficiency = …………………………………………………… X 100
SS of cylinder
=> 90 = (2400 – x) / 2400 X 100 (Let, SS of worker roller be x)
=> 90 X 2400 = 240000 – 100x
=> 100x = 240000 – 216000
=> X = 2400/100 = 240 ft/min (ANS)
2. Find out the wt/100yd of BC sliver when,
Dollop wt. = 30 lb
Clock length = 12.23
Draft = 11.23
Evaporation and short fibre loss = 4%
Solution:
We know, Breaker card sliver wt. /100yd = (Dollop wt.) / (Clock length) X 100 X Doubling /
Draft X Waste%
= 30/12.9 X 100 X 1/11.23 X (100 – 4)/100
= 19.88 lb/100yd. (ANS)
3. If B/C draft is 12, dollop wt. is 38 lb and Clock length (CL) is 14.4 yd, Then find –
Feed sliver wt./100yd,
Delivered sliver wt./100yd.
Solution:
Feed sliver wt./100 yd = DW/CL X 100
= 38/14.4 X 100
= 263.89 lb.
Delivered sliver wt./100yd = 263.89/Draft
= 263.89/12
= 21.99 lb. (ANS)
4. A B/C is working with 14.4 yd CL having FR speed of 6.94 rpm and dia 9.75 inch. What
will be the time reqd to feed one dollop of 36 lb?
Solution:
Given,
CL = 14.4 yd
FR speed = 6.94 rpm
FR dia = 9.75 inch
Dollop wt. = 36 lb
Time to finish one dollop =?
Distance traversed by the feed roller in one min = πdn = π X 9.75 X 6.94 inch/min
= 3.14 X 9.75/36 X 6.94 yd/min
= 5.90 yd/min.
Time required to feed one dollop = (CL in yd)/SS of FR in yd
= 14.4/5.9 min = 2.44 min (ANS)
5. A B/C is running with a CL 12.9 yd and DW 30 lb. having SS of feed roller 18 feet/min. If
the efficiency of B/C is 80% and evaporation loss is 4%, then what will be the
production/shift in metric ton? [1 MT = 2204 lb]
Solution:
Given,
CL = 12.9 yd
DW = 30 lb
SS of feed roller = 18 feet/min
Evaporation loss = 4%
Efficiency =80%
Production/shift =?
We know,
Production/shift = SS of feed roller in inch/min X 60 X DW/Cl X Eff% X Waste%
= 18/3 X 30/12.9 X 80/100 X (100 – 4)/100 X 60 X 8 X 1/2204
= 2.33 (ANS)
Jute Carding:
In jute spinning, carding is the major area for jute yarn production process. In jute carding
machine the primary function of jute carding is done by the action of worker and cylinder and
the cleaning and the cleaning actions is done between worker and stripper. For jute yarn
production, some calculation formulas of jute carding are given below.
Jute Carding
Some important formulas for jute carding –
Surface speed (SS) of cylinder roller – SS of worker roller
1. Carding efficiency = ………………………………………………………………
Surface speed (SS) of cylinder
SS of cylinder
2. Carding Ratio = ……………………………
SS of worker
Dollop wt.
3. Wt. of feed sliver/100 yd = ……………………… X 100%
Clock length
Doubling
4. Wt. of delivery/100 yd = wt. of feed sliver/100yd X …………………..
Draft
Dollop wt. Doubling
= …………………… X 100 X …………………..
Clock length Draft
SS of delivery roller
5. Mechanical Draft = ……………………………
SS of feed roller
Calculated feed sliver wt. /100 yd
= ……………………………………………………………..
Calculated delivered sliver wt. /100 yd
Wt. /100 yd of feed material
6. Actual draft = ……………………………………….. X Doubling X Waste%
Wt. /100 yd of delivered material
= Mechanical draft X Waste%
7. Draft constant = DCP X Draft
8. SS of feed roller = π X Dia in inch X Speed
Length of feed material
= ……………………………………….
Doubling
SS of delivery roller
= ………………………………….
Draft
9. SS of delivery roller = π X Dia in inch X Speed
= SS of delivery roller X Lead%
10. Finisher card sliver wt. /100 yd
B/C sliver wt. /100 yd
= ………………………………………. X Doubling X Waste%
F/C draft
Dollop wt. B/C doubling F/C doubling
= …………………… X 100 X ………………… X ………………… X Waste%
Clock length B/C draft F/C draft
11. Production /hr = SS of delivery roller in inch /min X 60/36 X wt. of sliver/yd X Eff% X
Waste%
Dollop wt.
= SS of feed roller in inch/min X 60/36 X ……………………. X Eff% X Waste%
Clock length
Some Problems and Solutions:
1. The surface speed of cylinder is 2400 feet/min. If the carding efficiency 90%, then what
will be the SS of worker roller.
Solution:
SS of cylinder – SS of worker
Carding efficiency = …………………………………………………… X 100
SS of cylinder
=> 90 = (2400 – x) / 2400 X 100 (Let, SS of worker roller be x)
=> 90 X 2400 = 240000 – 100x
=> 100x = 240000 – 216000
=> X = 2400/100 = 240 ft/min (ANS)
2. Find out the wt/100yd of BC sliver when,
Dollop wt. = 30 lb
Clock length = 12.23
Draft = 11.23
Evaporation and short fibre loss = 4%
Solution:
We know, Breaker card sliver wt. /100yd = (Dollop wt.) / (Clock length) X 100 X Doubling /
Draft X Waste%
= 30/12.9 X 100 X 1/11.23 X (100 – 4)/100
= 19.88 lb/100yd. (ANS)
3. If B/C draft is 12, dollop wt. is 38 lb and Clock length (CL) is 14.4 yd, Then find –
Feed sliver wt./100yd,
Delivered sliver wt./100yd.
Solution:
Feed sliver wt./100 yd = DW/CL X 100
= 38/14.4 X 100
= 263.89 lb.
Delivered sliver wt./100yd = 263.89/Draft
= 263.89/12
= 21.99 lb. (ANS)
4. A B/C is working with 14.4 yd CL having FR speed of 6.94 rpm and dia 9.75 inch. What
will be the time reqd to feed one dollop of 36 lb?
Solution:
Given,
CL = 14.4 yd
FR speed = 6.94 rpm
FR dia = 9.75 inch
Dollop wt. = 36 lb
Time to finish one dollop =?
Distance traversed by the feed roller in one min = πdn = π X 9.75 X 6.94 inch/min
= 3.14 X 9.75/36 X 6.94 yd/min
= 5.90 yd/min.
Time required to feed one dollop = (CL in yd)/SS of FR in yd
= 14.4/5.9 min = 2.44 min (ANS)
5. A B/C is running with a CL 12.9 yd and DW 30 lb. having SS of feed roller 18 feet/min. If
the efficiency of B/C is 80% and evaporation loss is 4%, then what will be the
production/shift in metric ton? [1 MT = 2204 lb]
Solution:
Given,
CL = 12.9 yd
DW = 30 lb
SS of feed roller = 18 feet/min
Evaporation loss = 4%
Efficiency =80%
Production/shift =?
We know,
Production/shift = SS of feed roller in inch/min X 60 X DW/Cl X Eff% X Waste%
= 18/3 X 30/12.9 X 80/100 X (100 – 4)/100 X 60 X 8 X 1/2204
= 2.33 (ANS)