RAW MATERIAL CALCULATIONS


Introduction

  • In calculations of cloth, important raw material calculations which are often required during raw material calculation are to estimate
    • the amount of material in a piece of cloth of given dimensions and
    • the amount of different types of yarns required to produce a cloth similar to given sample.
  • In RAW MATERIAL CALCULATIONS, we need to add on the waste made in weaving as well as in the preparatory processes.
Various other factors need to be taken care during calculation:
  - Contraction of Weft and Warp.
  - No. of intersections
  - Reed Count


What is Felting wool ? | Shrinkage of Wool | Relaxation




RAW MATERIAL CALCULATIONS

Quantity of Material


All the calculation are done using the following formulas

  • Total Quantity of Material in a piece of cloth = Weight of Yarns + Sizing Materials
  • Total weight of Yarns = Wt. of Warps + Wt. of Wefts
  • Tape Length = Length of piece + Crimp/ Regain/ take-up
  • Ends per inch = Reed Count * Reed Width
  • Total No. of Warp Ends = Body Warps + Selvedge Warps
  • Total Length of Warp = Total Warps * Tape Length
  • Wt. of Warp Yarns = Total Length of Warps/ Warp Count
  • Total No. of Weft Ends = Picks per inch * Length of Piece

  • Total Length of Weft = Total Wefts * (Width of cloth + Crimp)
  • Wt. of Weft Yarns = Total Length of Wefts/ Weft Count
  • Number of Repeats = (Total warps – selvedge warps)

Repeat size

  • No. of Yarn Package required = Total yarn weight/ Yarn Weight per Package

Numerical based on raw material calculation


Example 1


Grey and Mono-coloured Plain Fabric –


A cloth 44.5 inches wide on a 72’s Stockport reed is woven with 32’s Warp and 40’s Weft and 64 picks per inch. Selvedges ¼” on each side, are drawn 4 ends per dent. The count of the selvedge yarn is same as that of the warp yarn. The length of piece is 40 Yards. If regain of the warp is 5%, calculate –

a.) Total No. of Ends in Warp.

b.) Total Length of Warp Yarn in Hanks.

c.) Total weight of warp yarn in the piece.

d.) Total weight of weft yarn in the piece.

e.) Total weight of yarn in the piece.



Given Particulars



Cloth Width
44.5 inch
Selvedge width
¼ inch each
Reed Count
72’s Stockport
Selvedge Denting
4:4
Warp Count
32’s
Selvedge Yarn Count
Same as Warp Count
Weft Count
40’s
Length of piece
40 Yards
PPI
64
Warp Crimp/ Regain
5%
Assumed Particulars

Body Warp Denting
2:2
Weft Crimp
0%
Waste
0%

Quick Calculations

Dent per Inch
72/2 = 36
Total No. of Dents for Body
44 * 36 = 1584
Total No. of Body Warps
1584*2 = 3168
Total No. of Dents for Selvedge
(1/4+1/4) * 36 = 18
Total No. of Selvedge Warps
18*4 = 72
Tape Length
40 + (40*0.05) = 42 Yards


Sol:

(a) Total No. of Warps = 3168 + 72 = 3240

(b) Total Length of Warp Yarns = 3240*42/840 = 162 Hks

(c) Wt. of Warps = 162/ 32 = 5.06 lbs

(d) Wt. of Wefts = 40*64*44.5/(840*40) = 3.4 lbs

(e) Total wt. of yarns = 5.06 + 3.4 = 8.46 lbs



Example 2


Given Particulars



Fabric Design
Stripe Plain
Selvedge width
¼ inch each
Reed Count
84’s Stockport
Selvedge Denting
4:4
Cloth Width
40.5 inch
Selvedge Yarn Count
2/42’s Bleached Cotton
Weft Count
50’s
Length of piece
30 Yards
PPI
72
Warp Crimp/ Regain
4%


Given Particulars



Fabric Design
Stripe Plain
Selvedge width
¼ inch each
Reed Count
84’s Stockport
Selvedge Denting
4:4
Cloth Width
40.5 inch
Selvedge Yarn Count
2/42’s Bleached Cotton
Weft Count
50’s
Length of piece
30 Yards
PPI
72
Warp Crimp/ Regain
4%




Repeat Pattern for Warp
40’s Dark Brown
3 Ends
36’s White
3 Ends
32’s Green Printed
1 Ends
36’s White
3 Ends
36’s Light Brown
5 Ends
2/50’s Grandrelle (Dark Yellow & White)
1 Ends
36’s Light Brown
5 Ends
Calculate –

(a) Total No. of Ends in Warp.

(b) Total Length of each coloured Yarn in Hanks.

(c) Total weight of each coloured yarn in the piece.

(d) Total weight of yarn in the piece.



Assumed Particulars

Body Warp Denting
2:2
Weft Crimp
0%
Waste
0%


Quick Calculations

Dent per Inch
84/2 = 42
Total No. of Dents for Body
40 * 42 = 1680
Total No. of Body Warps
1680*2 = 3360
Total No. of Dents for Selvedge
(1/4+1/4) * 42 = 21
Total No. of Selvedge Warps
21*4 = 84
Tape Length
30 + (30*0.04) = 31.2 Yards
Repeat Size
3+3+1+3+5+1+5 = 21


Sol: (a) Total No. of Warps = 3360 + 84 = 3444

Number of Repeats = 3360/ 21 = 160






Total No. of 40’s Dark Brown Ends
3 Ends
3*160 = 480
Total No. of 36’s White Ends
6 Ends
6* 160 = 960
Total No. of 32’s Green Printed Ends
1 Ends
1*160 = 160
Total No. of 36’s Light Brown Ends
10 Ends
10*160 = 1600
Total No. of 2/50’s Grandrelle (Dark Yellow & White) Ends
1 Ends
1*160 = 160



(b) Length of Warp Yarns



Total length of 40’s Dark Brown Ends
3 Ends
3*160 = 480
480*31.2/840 = 17.9 Hks
Total length of 36’s White Ends
6 Ends
6* 160 = 960
960*31.2/840 = 35.7 Hks
Total length of 32’s Green Printed Ends
1 Ends
1*160 = 160
160*31.2/840 = 5.95 Hks
Total length of 36’s Light Brown Ends
10 Ends
10*160 = 1600
1600*31.2/840 = 59.5 Hks
Total length of 2/50’s Grandrelle (Dark Yellow & White) Ends
1 Ends
1*160 = 160
160*31.2/840 = 5.95 Hks
Total length of 2/42’s Bleached Selvedge Ends
84 Ends

84*31.2/840 = 3.12 Hks






(c) Weight of Yarns

Total length of 40’s Dark Brown Ends
480*31.2/840 = 17.9 Hks
17.9/40 = 0.446 lbs
Total length of 36’s White Ends
960*31.2/840 = 35.7 Hks
35.7/36 = 0.992 lbs
Total length of 32’s Green Printed Ends
160*31.2/840 = 5.95 Hks
5.95/32 = 0.186 lbs
Total length of 36’s Light Brown Ends
1600*31.2/840 = 59.5 Hks
59.5/36 = 1.653 lbs
Total length of 2/50’s Grandrelle Ends
160*31.2/840 = 5.95 Hks
5.95/25 = 0.238 lbs
Total length of 2/42’s Bleached Selv Ends
84*31.2/840 = 3.12 Hks
3.12/21 = 0.148 lbs
Total Weight of Warp Yarns

3.663 lbs
Total Weight of Weft Yarns
30*72*40.5/(840*50)
2.083 lbs
(d) Total weight

5.746 lbs



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RAW MATERIAL CALCULATIONS RAW MATERIAL CALCULATIONS Reviewed by Suraj Gupta on July 28, 2020 Rating: 5

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