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Different Formulas of Weaving Calculation

Different Formulas of Weaving Calculation
Raju Tex
Production Executive,
B.J.Group, Mawna, Gazipur
Chittagong Textile Engineering College
Facebook: https://www.facebook.com/ERZRAZU





Weaving Calculations:
The process of producing a fabric by interlacing warp and weft threads is known as weaving. The machine used for weaving is known as weaving machine or loom. Weaving calculation is very important to produce fabric. It is also very critical task for weaving master. Different formulas and calculation of weaving are given in this article.
Weaving Calculation
Weaving process
Different Formulas of Weaving Calculation:

Reed Count
It is calculated in stock port system.No. of dents in 2 inches is called Reed Count.

                                     EPI
Reed count = ……………………..
                      1 + Weft crimp percentage

Reed Width

                                            100 + Weft crimp percentage
Reed Width = Cloth width X ………………….....................…
                                                           100

Cloth Cover Factor

                                           EPI
1. Warp cover factor = …………………….
                                    √Warp Count

                                           PPI
2. Weft cover factor = ……………………..
                                   √Weft Count

                                                                  Wp.C.F. X Wt.C.F.
3. Cloth cover factor = Wp.C. - F Wt.C.F + …………………………
                                                                              28

Crimp % :
Crimp Percentage is defined as the mean difference between the straightened thread length and the distance between the ends of the thread while in cloth, expressed as a percentage.

                           Warp length - Cloth length
Warp crimp% = …………………………….. X 100
                                  Cloth length

                       Weft length - Cloth length
Weft crimp% = …………………………….. X 100
                               Cloth length

Loom:

                                              Motor pully diameter
Loom Speed = Motor RPM X …………...…………..
                                              Loom pully diameter

                                       Actual Production
Loom Efficiency (%) = ………………………….. X 100
                                    Calculated Production

Fabric Specification:

                                          EPI X PPI
Fabric specification = …………………………. X Fabric width
                                   Warp count X weft count

Or

                                   Warp count X weft count
Fabric specification = …………………………. X Fabric width
                                           EPI X PPI

Weight of yarn in a cloth:
The weight of cloth manufactured on looms depends upon the weight of yarns in the warp and weft: ends/inch, picks/inch and the weight of size on the warp.

Therefore, Cloth weight = Weight of warp + Weight of weft + Weight of size (All in lbs.)

                                                      Total No. of Ends X Tape Length in Yds.
Where as Weight of warp in lbs. = ……………………………………………………..
                                                              840 X Warp Yarn Count

                                           Length of Cloth (Yds) X Picks / inch in Cloth X Reed Width (inch)
Also Weight of weft in lbs.= ……………………………………………………………………….
                                                                 840 X Weft Yarn Count

Weving Calculations:
Calculating linear yards of fabric produced on a weaving machine per hour of operation can be done using the following formula:

Linear Yards/Hour = (picks per min. / picks per in.) x (60 min. per hr. / 36 in. per yd) x loom efficiency (%)

Linear Meters/Hour = (picks per min / picks per centimeter) x (60 min. per hr. / 100 cm per meter) x loom efficiency (%)

Square Yards/Hour = Linear Yards Per Hour x Fabric Width (Yds.)

Square Meters/Hour = Linear Meters Per Hour x Fabric Width (Meters)

Rate of Filling Insertion (Yards/Min) = Loom Speed (Picks/Min) x Loom Width (Yds.) x Loom Efficiency (%)

Rate of Filling Insertion (Meters/Min) = Loom Speed (Picks/Min) x Loom Width (Meters) x Loom Efficiency (%)

Exmple of Weving Calculations:

Example-1:
What are the linear yards of fabric produced on a machine running 650 picks per minute, inserting 58 picks per inch, and operating at a 92% efficiency?

Linear Yards/Hour = (picks per min. / picks per in.) x (60 min. per hr. / 36 in. per yd) x loom efficiency (%)

Linear Yards/Hour = (650picks per min. / 58picks per in.) x (60 min. per hr. / 36 in. per yd) x .92 loom efficiency

Answer: 17.2

Example-2:
What is the rate of filling insertion in a loom running 720 picks per minute with a width of 2.5 meters at 93% efficiency?

Rate of Filling Insertion (Meters/Min) = Loom Speed (Picks/Min) x Loom Width (Meters) x Loom Efficiency (%)

Rate of Filling Insertion (Meters/Min) = 720(Picks/Min) x 2.5 (Meters) x .93 Loom Efficiency

Answer: 1674 meters of filling inserted per minute

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