PRODUCTION CALCULATION

Production Calculation:

SIZING RECIPE

IMPORTANT SIZING RECIPE:


Formula for Size pick up% :-

Pickup% = {(sized yarn - unsized yarn)/unsized yarn}x100

Pick up% range = 8-15

 

 Sizing%=root(T.Ends/Sum of root constn)

Sum of root constn= root(epi)root(ppi)root(wp cnt)root(wf cnt)

Formula

 No of section= T.E / No of ends/repeat

For (Yds sample) cone length=No of section X warping length


Exa: Cone length= 20 X 120(mtr)
                             2400 mtr (for each color)

***. Formula:No. of section=Total Ends/(No of end/repeat)


***.Cone length for ydg sample=No of section X Warping length


***.Formula: Mtr/Kg (in dyeing program)


(No.of cone X Cone length)/(1693.34 X Count)=Mtr/kg in dyeing Program




***. Formula: Avg Reed count:

For : 40X40/118X80

1st step: find single dent

Ex-

900 ends-2 dent/reed= 450ends (single)
100 ends-1 dents/reed=100 ends (single)
......................................................................
total 1000 ends                   = single ends/dent(650) 

2nd steps: find ratio


ratio=Total ends/(single ends/dent)

Ex-

1000/650=1.538



3rd step:find avg reed count


(approximate reed count/2 ) X ratio


Ex-

(144(appro.reed count)/2) X1.538(ratio)=110 (EPI)


for finish EPI=110{(G.EPI)X61(G.with)}/57(F.with)



=118 (finished EPI)

GSM FORMULA

GSM

IMPORTANT FORMULA FOR WEAVING

7.Formula:Total Ends

*Total Ends=EPI X F.F.Width


8.Formula:

*Reed space={(Total ends-50)/Reed count}/(Ends/dent X 2)


8.Formula:Beam width


*Beam width=(Total Ends/Reed count)/(Ends/dent*2)


9.Formula:Reed count

*Reed count=EPI*F.Fabrics width/Reed spece (For Plain)

*Reed count=EPI*0.9 (For Twill)

*Reed count for Bl prodn=Grey EPI-4%(For Normal Fabrics,1/1 Plain)
                                       =Grey EPI-6%(For Lycra Fabrics,1/1 Plain)

10.Formula:Consumption for fabrics

* Wt in kg(warp)=(T.E/768/Count/2.2046)+crimp%+Wastage%

* Wt in yds(warp)=(T.E/840/Count)+crimp%+Wastage%



* Wt in kg(weft)={(Reed spece+4)*PPI}/{768/Count/2.2046)}+crimp%+Wastage%

* Wt in yds(weft)={(Reed spece+4)*PPI}/{840/Count)}+crimp%+Wastage%

10.Formula:Individual color %

*Individual color %= (No.of Ends*100)/Total Ends of warp yerans

11.Formula:Individual color Qty in kgs

*Individual color Qty in kgs=(Total kgs*Color%)/100

IMPORTANT FORMULA FOR WEAVING: Wp in kg/yds=T.E/(840/Count/2.2046)& To convert kg/mtr to kg/yds= kg/mtr/1.08constant.

1.Formula: Count


*Count= L/LuX Wu/W(Indirect system)
*Count=Lu/LXW/Wu (Direct system)


2.Formula: Diameter of yarn

*Diameter of yarn= 1/28 root count


3.Formula: G.S.M

*G.S.M=(EPI/Count+PPI/Count)X 25.6


4.Formula: Cover factor

*Cover factor=(EPI/ root count+PPI/ root count)X 0.88 to 1(according to weave)


5.Formula: Grey EPI

Grey EPI=(F.EPI X F.Width)/G.Width


6.Formula: Grey Width

*Grey width=(F.EPI X F.Width)/G.EPI