Weaving Calculations FM-4023 (Part 1)
Weaving Calculations FM-4023 (Part 1)
Weaving Calculations FM-4023 (Part 1)
Zuhaib Ahmad
Indirect System
Direct System
( )
( )
( )
( )
4. Decimal Count = = 7
( )
( )
( )
( )
Sr #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
( )
1.
= = 1000
2.
= = 9000
3.
/ = 10000
4.
= =
1000
5. Metric Count = = ( ) = ( )
27.34
( )
( )
( )
( )
( )
( )
( )
( )
( )
( )
( )
Name of System
English cotton
French cotton
Bump cotton
Decimal (for all yarns)
Metric
Worsted
Woolen (Yorkshire Skein)
Unit of weight
1 lb.
kg.
1 oz.
1 lb
1 kg.
1 lb.
6 lb.
Unit of Length
Hank of 840 yards
Hank of 1000 meters
1 yard
Hank of 1000 yards
Hank of 1000 meters
Hank of 560 yards
Skein or Hank of 1536 yards
1 lb.
1 lb.
1 lb.
1 lb.
1 grm.
1 grm.
1 grm.
1 dram = 27.34 grains
Fall 2012
8th Semester
Zuhaib Ahmad
( )
( )
( )
( )
( )
( )
( )
10. If 240 yards of cotton yarn weight 40 grains, what is the count of yarn in English cotton
system?
11. Find the weight of 270 yards of 60S cotton.
12. What is length of 105 grains of 40S cotton yarn?
13. How many hanks are contained in 5 bundles of 80S cotton yarn?
14. Find the count in worsted system of yarn if 650 m weigh 55 grains.
15. If 840 yards of worsted yarn weigh 50 grains. What will be the count of yarn?
16. The weight of 768 yards of woolen yarn is 0.25 lbs. What is the count of yarn?
17. Calculate the count in French cotton system of 100 m of cotton yarn if weight is 4 grams.
18. If the weight of 60 km of cotton yarn is 5 kgs. What is the count of yarn in French cotton
and metric system?
19. 45 yards of cotton was found to be weigh 5 grains. Calculate its count in decimal system?
20. If 96 yards of waste yarn weih 4 lb. What is the count of yarn in Bump cotton system?
( )
21. Show that in direct system = = 1000 ( )
22. Show that in direct system = = 9000
23. Show that in direct system / = 10000
1000
( )
( )
( )
( )
( )
( )
If 350 meters of silk yarn weigh 7.5 grains. What is the count of yarn in denier system?
What is the weight of 270 meter of Nylon yarn whose count is 200 denier.
Calculate the count of 5000 yards of cotton yarn in Tex system, if its weight is 10 ounces.
The length of a quality of 42 Tex Nylon is 7 Km. Calculate the weight of yarn in ounces?
If 27432 yards of acetate yarn weight 240 grams. What is its count in Tex and Grex system?
Find the length of 40 ozs & 11 drams of silk yarn, whose count is 150 drams.
If 7200 yards of Jute yarn weigh 3 lbs. What is the count of yarn in direct system?
Count Conversions
1. Indirect to Indirect:
If
1
2
2 = 1 [
]
2
1
2. Direct to Indirect:
1
1
2
2 = [
]
1
2
1
3. Direct to Direct:
Fall 2012
8th Semester
Zuhaib Ahmad
2
1
2 = 1 [
]
1
2
4. Indirect to Direct:
2 =
1
2
1
[
]
1
1
2
When we will use indirect to direct, the given or known count will be indirect and when we
will use direct to indirect formula then given or known count will be direct.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
1
1
1
=
+
1 2
= 1 + 2
1
1
1
1
=
+
+ +
1 2
Fall 2012
= 1 + 2 + +
8th Semester
Zuhaib Ahmad
Where;
R1 = Count of 1st individual yarn
R2 = Count of 2nd individual yarn
And if,
A= Count of 1st yarn
Fall 2012
8th Semester
Zuhaib Ahmad
4) A folded yarn is composed of one thread of 14 Tex & other of 12 Tex. Their price is Rs9
&Rs 10 per pound respectively. Calculate the cost of folded yarn, if CC is 0.35Rs/kg.
Condition Count
All textile materials are more or less hygroscopic. They contain a certain amount of moisture,
depending on the relative humidity of the surrounding atmosphere in which they are kept. So
in determining the weight of the yarn or a fabric it is necessary to have the weight taken
under standard condition. Also while selling or purchasing cotton yarn their price is fixed on
their conditioned weight.
= 8.33
()
()
= 1000
While = + ( 100 )
WO = Oven dry weight
1. The conditioned count of a yarn is 20s cotton. What is the oven dry weight of 16 hanks of
such yarn?
2. Calculate the conditioned count of cotton yarn in Tex system, if oven dry weight of 24km
yarn is 32gms.
3. If the oven dry weight of 7200 yds of Jute yarn is 2lbs. then calculate its conditioned count
(direct system). The %age of M.R of Jute is13.75%.
Average Count
The term average count indicates the calculated count determined from the total length and
total weight of the different counts of yarn in question. And by this total length and total
weight we can find the average count in the required system.
1.
Calculate the average count of 80/S, 50/S, 40/S and 20/S cotton yarn.
C1:C2:C3:C4
80:50:40:20
Taking L.C.M. of all four counts.
L.C.M.= 400
Fall 2012
8th Semester
Zuhaib Ahmad
( )
( )
( )
( )
400
400
400
400
80
50
40
20
= 5
= 8
= 10
= 20
And,
( )
( )
1600
43
= 37.2S
2. A warp is composed of 40/2 and 30/1 cotton yarn in proportion of 2 ends of 40/2 & 12 ends
of 30/1 yarn. Calculate the average count of yarn in warp.
3. A warp consists of yards of following particulars. Calculate the average count;
(a) 3lbs of 20s yarn. (b) 6lbs of 16s yarn. (c) 9lbs of 24s yarn.
4. A warp contains yarns of following particulars. Calculate average count in English System.
a) 4 ends of 30 Tex. (b) 16 ends of 40 Tex.
5. Given a compound twisted thread, which is made up of one thread of 20 N e spun viscous,
one thread of 20/2 ply Ne worsted & one thread of 80 denier polyester filament yarn. Find
the resultant yarn count in the Tex, denier & cotton system.
6. A spurl yarn is composed of one end of 40/2 Ne spun viscous yarn, one end of 50 Ne polyester
viscous yarn & one end of 84 denier polyester filament yarns. It is found on measurement
that 10cm of spun yarn contains 12cm of 40/2 ply Ne yarn, 15cm of 50 Ne& 20cm of 84
denier yarn. Find the resultant count in Tex system.
7. Calculate the count of cork screw yarn produced by twisting together one thread of 40/2 &
other 10/1 by actual measurement. It was found that 20 inch of 10/1 thread & 10 inch of 40/2
are contained in 10 inch of folder yarn.
Winding Production
There are two ways to measure the winding production
Production by Length
1. =
Production by Weight
3. =
= (/) 60
2. =
(/) 60
840
4. =
. (/) 60 .
=
100
Fall 2012
. (/) 60 .
840 100
8th Semester
Zuhaib Ahmad
Where,
n= number of spindles
Ne = English Count
And
% =
=
=
100%
Warping Production
There are also two ways to measure the warping production
Production by Length
1. =
Production by Weight
3. =
= (/) 60
2. =
. (/) 60 .
=
100
Fall 2012
/ 60
840
4. =
8th Semester
Zuhaib Ahmad
. (/) 60 .
840 100
And, % =
100%
1) Calculate the actual production in meters of high speed warping machine for 16 hours. If
warping rate is 750 yds/min and overall efficiency is 75%.
2) Calculate the production in bags of warping machine running at 950 m/min for 24 hrs. If
warp is 12 Tex cotton yarn with 640 ends is being warped. Overall efficiency of machine s
60%.
3) Calculate the efficiency of high speed warping machine running at 650 m/min for 9 hrs of a
day. If actual production for this duration is 191282 yards.
4) A high speed warping machine with warping rate of 880 yards/min is preparing a standard
warp of 525 ends. If count of yarn is 150 denier and overall efficiency is 84% and the length
of warp on beam is 44352 yards, calculate
a) Length of warp being produced for 8 hrs (one shift) of a day.
b) No. of beams being produced per shift.
c) Weight of yarn in lbs for one shift.
d) Weight of yarn on one beam in lbs.
5) Calculate the time required to prepare a set of 8 warpers beam on two warping machine
running at 560 yards/min. The length per beam is 36000 yards and overall efficiency is 60%
6) Ie is required to produce a warp length of 6,30,000 yards with 480 ends on 4 warping
machines. If warping speed is 800m/min. Calculate the time required to prepare the warp
set if efficiency is 85%.
/
/
Where,
Ew= Maximum number of ends/warp beam = Warping Creel Capacity
Es= Maximum number of ends/sized beam
Set Calculation
Question: 18 weavers beam with 1850m of sized warp are to be produced on sizing machine.
Total number of ends in the sized warp is required to be 7680 of 20 Tex cotton yarn. If back
beams are produced on warping with 650 creel capacity, calculate the following if waste on
sizing is 0.75%:
Fall 2012
8th Semester
Zuhaib Ahmad
Solution:
Number of weavers beam = 18
Length of Weavers beam = 1850 Mtr
Number of ends/weavers beam = 7680 = Total Ends
Creel Capacity = 650
590 .6
Warp Count = 20 Tex = 20 = 29.53
Sizing waste = 0.75%
Cone Remainder = 1.5%
Now solving each required quantity:
. =
. / 7680
=
= 11.82 12
650
. / =
7680
=
= 640
.
12
100
Where, = [ / . ]
0.75
= 1850 18 +
1850 18 = 33550
100
.
840
33550 1.0936 640
=
= 946.65
840 29.53
/ () =
= / .
= 946.65 12 = 11359.8
. =
+ {
. }
100
100
1.5
11359.8 + (100 11359.8)
=
= 115.3 116
100
Fall 2012
8th Semester
/ =
Zuhaib Ahmad
.
840 .
=
/10 =
/ 107
.
=
118.33 107
= 4.59
33550 7680
Sizing Calculation
= (/) 60
=
(/) 60 .
100
(/) 60
840
(/) 60 .
840 100
+
/
. =
+
/
Size %age
% =
100
S%=Size %age
100
100 + %
()
=
840
()
=
840
Fall 2012
10
8th Semester
Zuhaib Ahmad
.
100
.
%= Concentration
. ()(100 )
. ()
. ()(100 )
. =
100
. = Solid content in kg
% =
. = + . + (. ( )
= . . (. ( )
. 100
=
(. ( )
100 + .
(%) (%)
100
( ) %
() =
100
(%) ( )
. . =
100
() 100
% =
()
% =
Y (l/cm)
1800
5.8
2000
6.4
2200
7.0
2400
7.6
2600
8.2
= (
Fall 2012
11
8th Semester
Zuhaib Ahmad
1. Calculate the actual production of sizing m/c in meters and lbs for 8 hrs. If it is
running at 75m/min. A warp of cotton with 7404 ends is sized on sizing m/c and
efficiency of m/c is 55%.
2. The actual prod. of sizing m/c is 80 m/min. how much time will be required to size a
set of 23500m. the waste %age in sizing is 0.5% and elongation in size yarn is 1.5%.
3. Calculate the time required to size a set of 150 denier warp of length33500 meters. If
sizing m/c speed is 60m/min the waste %age of sizing is 0.5% and elongation of warp
is 1.2%. m/c is running at efficiency of 55%.
4. A set of 12 back beams containing 23500m of warp is being sized on sizing m/c. If
elongation of warp is 1.75% and waste of warp is 1.25%. Calculate the no of Wvr`s
beam if length of sized warp/wvR beam is 3500 yds.
5. An unsized warp of 2500m is req. to be sized to 16% on its wt. if total no of ends in
warp is 7650 and count of warp is 15 tex. calculate
a) Wt of size on warp in kgs.
b) Wt of sized warp in kgs.
c) Count of sized warp.
6. A sized beam contains 40 kg of sized warp of 1000 m long. The count of unsized
warp is 12 tex if the no of ends in the warp are 2500. Calculate
a) Wt of size on warp
b) %age of size on yarn
c) Count of sized yarn
7. A warp containing 7404 is req. to be sized to 1.5%. the length of size warp on weaver
beam is req. to be 3200 m . if count of yarn is cotton. Calculate
a) Wt of size on warp
b) %age of size on yarn
c) Count of sized yarn
8. A 20 tex. yarn is sized to 24 tex. Determine the size %age in yarn.
9. 400(liter) of size solution are to be cooked. Its concentration is 10%. Calculate the
sizing material required if water content of size material are 20%.
10. 640 liter of size solution was added with 80 kg of sizing material. If water content of
size material are 18%. Cal. The concentration of sol.
11. Find the amount of size solution in kgs. If 82 kg of size sol was added to achieve
10.5% concentration. The water content in size material are 17%.
12. How much solid content will be present in 680liters of S.Sol. If its concentration is
11.5%.
13. 640 liters of size solution with 10.5% conc. Are to be cooked and condensation
allowance of steam was found to be 15%. If water content of S.M were 20%.
Calculate the water volume if specific volume of size material is 0.7 liter/kg.
14. 660 liters of S.S with 90kg of S.M are to be cooked with 500 liters of water volume.
Calculate the condensation allowance in liters and %age if specific volume of
material is 0.7
15. What will be the S.Sol. Absorption (size pickup) if 500 ends with 30/1 of length
1000m are being sized. The working width of size warp is 2200m Take as 20cm.
Fall 2012
12
8th Semester
Zuhaib Ahmad
16. Calculate the degree of sizing material in %age and kgs for 7404 ends of 30/1 having
23500m. the size absorption is 152% and conc. Is 11%. Also cal. the S.S req. in kgs.
17. Calculate the size solution req. per hr for a warp of 19.68 tex having no of ends 7404
to sized at 55% efficiency of m/c. The size solution absorption 145% and m/c is
running at 65m/min S.S.R=? .
18. A 20 tex cotton is cooked as having size %age of 12%age. Determinethe oven dry
mass of size added per kg of unsize warp. The standard regain of cotton is 8.5%.
19. A 24 tex cotton warp containing 6750ends has 11% size added in each lb of size
paste. There are 40 grm of solid ingredients. The max drying capacity of drying zone
is 550kg/hr. Cal. The max running speed which ensures that regain of sized yarn in
weaver`s beam is 6.5%.
20. A 20 tex warp containing 5000 ends nhas 12% added in each kg of size paste. There
are 80 grm of solid ingredient. The max drying capacity of drying zone 450kg/hr.
Cal the max running speed which ensures regain of sized yarn 6%.
21. What will be the warp produce in kgs, if evaporate power of dryer is 450kg/hr and
size solution absorption is 150%. The size yarn required 14% size add on.
22. Cal. The rate of evaporation of dryer, if a set of 20/1 cotton with 8064 ends at
55m/min is sized on sizing m/c at 58% efficiency. The size solution absorption and
degree of sizing are 145 and 13% respectively moisture in sized yarn is req. 7%.
23. Prepare a size recipe to achieve size add on 16% with size pickup %age of 140% and
condensation allowance is 70 liter and 650 liter of size solution is req. to be
cooked.{70% capacity of vessel must be utilized} . {12~15% of final volume is
condensed experimental value.}
H2O = 501 liter
Starch = 53kg
PVA = 24kg
Acrylic = 30kg
Softener = 6kg
S.S = 650 liter
Fall 2012
13
8th Semester