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Textile Calculations and Equations

Production = no. of needle x no of feeder x RPM x stitch length/ yarn count Production per shift in KG at 100% efficiency

sheshir
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Textile Calculations and Equations

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  1. TEXTILE CALCULATION & EQUATION

  2. PREPARED BY ©right Name : MAZADUL HASAN SHESHIR ID: 2010000400008 Batch: 13th Batch (Session 2009-2013) Department: Wet Processing Technology Email: mazadulhasan@yahoo.com Blog: www. Textilelab.blogspot.com Southeast University Department of Textile Engineering

  3. Spinning Calculation and Equation

  4. Basic Conversions (Spinning) No Length Weight Time 1. 1 in = 2.54 cm 1 lb = 7000 gr 1 min = 60 sec 2. 1 yd = 36 in 1 lb = 16 oz 1 hr = 60 min 3. 1 m = 1.0936 yd 1 oz = 437.5 gr 1 shift = 8 hr 4. 1 Hk = 840 yd 1 kg = 2.2046 lb 1 day = 24 hr 5. 1 Hk = 7 leas 1 bag = 100 lb 1 day = 3 shifts

  5. Count Conversion Table (Spinning) Ne Nm Tex Grex Denier Ne= 1 xNe 0.5905 xNm 590.5 /Tex 5905 /Grex 5315 /Den Nm= 1.693xNe 1 xNm 1000 /Tex 10,000/Grex 9000 /Den Tex= 590.5 /Ne 1000 /Nm 1 xTex 0.1 xGrex 0.111 xDen Grex= 5905 /Ne 10,000 /Nm 10 xTex 1 xGrex 1.111 xDen Denier= 5315 /Ne 9000 /Nm 9 xTex 0.9 xGrex 1 xDen

  6. Draft & TPI Formulas

  7. Efficiency Percentage (Spinning) Efficiency (%) Cleaning Efficiency (%) Twists per inch

  8. PRODUCTION CALCULATION FORMULAS

  9. PRODUCTION FORMULAS

  10. Yarn Count in Direct system Unit weight Unit length Uses System Tex Denier D-Tex Pounds/Spyndle Grams Grams Grams Pounds 1,000m 9,000m 10,000m 14400yds Polyester Lycra Lycra Jute Yarn Count in Indirect system System Unit weight Unit length Uses English (Ne) 1 lb 840 yds Cotton yarn Metric (Nm) 1 kg 1 km Cotton yarn Worsted 1 lb 560 yds Worsted yarn Woolen 1 lb 256 yds Woolen yarn

  11. Excellence of fiber quality by combing:

  12. Fabric (Knitting & Weaving) Calculation and Equation

  13. SIZING

  14. Calculation:

  15. Required Chemical &no. of Mixing of Sizing Recipe:

  16. Production is calculated in accordance with the following equation-

  17. Production calculation: 1. Production = no. of needle x no of feeder x RPM x stitch length/ yarn count Production per shift in KG at 100% efficiency Where, Ks = knitting constant Count = linear density of yarn GSM = gm per square meter Another formulae is : Stitch length = (Tex × Ks) / GSM Ks is a constant. Its value is different for different fabric structure and fabric type. Ks is calculated and estimated as below: Ks = (GSM x Stitch length) / Tex

  18. Production calculation: Ks = (GSM x Stitch length) / Tex Fabric type Color Value of Ks Single jersey Average 19.55 Single lacoste Average 22.4 Double lacoste Average 22.75 Polo pique Average 25 Plain interlock Average 39.3 1 X 1 rib Light 24.5 1 X 1 rib Average 26.5

  19. Relation between yarn count and m/c gauge seen in different m/c.:

  20. GSM Calculation

  21. DIFFERENT FABRIC GSM AND THEIR REQUIRED YARN COUNT S/J without lycra - Fabric G.S.M 110 - 120 120 - 130 130 - 140 140 - 150 150 - 160 170 - 210 Yarn Count 40 S – 36 S 36 S - 32 S 32 S – 28 S 28 S 26 S 24 S Rib without lycra - Yarn Count 36 S - 32 S 30 S 28 S 26 S 24 S 24 S Fabric G.S.M 180 - 190 190 - 200 200 - 215 215 - 230 230 - 250 250 - 300

  22. DIFFERENT FABRIC GSM AND THEIR REQUIRED YARN COUNT Interlock without lycra - Lacoste without lycra - Fabric G.S.M Yarn Count Fabric G.S.M Yarn Count 200 - 220 34 S 180 - 190 30 S 220 - 230 32 S 190 - 210 28 S 230 - 250 30 S 210 - 230 26 S 250 - 300 26 S 230 – 250 26 S 40D Lycra S/J – 40D Lycra Rib - Fabric G.S.M Yarn Count Fabric G.S.M Yarn Count 180 - 190 34 S 230 - 240 32 S 190 - 210 32 S 240 - 250 30 S 210 - 220 30 S 250 - 280 26 S 220 – 240 28 S 280 - 300 24 S 240 - 250 26 S

  23. Yarn Dyeing Calculation and Equation

  24. Production Calculation of Yarn singeing machine: Length = Count * Weight = Count * Weight * 840 yards = (Count * Weight * 840) / rpm yards per minute = (Count * Weight * 840) / rpm * 60 * 8 * 3 yards per day = (Count * Weight * 840) / rpm * 60 * 8 * 3 * 0.914 =……X…meter/day.

  25. Production Calculation of reeling machine:

  26. Production Calculation of hank to cone winding machine: Machine Parameter Yarn quality 58/2, 60/2 All single count Speed (rpm) 450 500 to 550 Length = Count  Weight = Count * Weight  840 yards = (Count  Weight  840) / rpm yards per minute = (Count  Weight  840) / rpm  60  8  3 yards per day = (Count  Weight  840) / rpm  60  8  3  0.914 =……X…meter/day.

  27. GSM Calculation: WPI = 32 CPI = 45 Stitch length = 3 mm Yarn Count = 20’S Ne

  28. Production Calculation Of Yarn Dyeing Machine : No. of Needle = π × Machine Diameter (D) × Machine Gauge (N) = 3.1416 × 30 × 24 = 2262 Yarn Count = 30/1 Ne No. of Feeder = 96 Machine RPM = 28 Stitch length = 3 mm Efficiency = 85% = 0.85 Shift = 8 hr. = 8 × 60 = 480 min Production of the machine is 146.407 Kg/Shift. Note: If any parameter in this calculation is changed then production capacity per shift will be changed.

  29. Package Density Calculation (Yarn Dyeing): Formula

  30. Density Calculation for Several Counts (Yarn dyeing): 1**Before Pressing • • • • • • Yarn Quality: 30/1 cc Package Height (H) = 162mm = 16.2cm Total Package Dia (D1) = 162mm = 16.2cm Total Package Weight (W1) = 1.38kg = 1380gm Spring Weight (W2) = 0.185kg = 185gm Spring Dia (D2) = 65 mm = 6.5cm

  31. Density Calculation for Several Counts (Yarn dyeing): 2 **After Pressing Yarn Quality: 30/1 cc Package Height (H) = 145mm = 14.5cm Total Package Dia (D1) = 165mm = 16.5cm Total Package Weight (W1) = 1.38kg = 1380gm Spring Weight (W2) = 0.185kg = 185gm Spring Dia (D2) = 65 mm = 6.5cm **So we can sure that after pressing for every count, yarn package density will be increase.

  32. Length Calculation in Package: To maintain the constant package density same length of yarn should be wound to all the packages of a batch or lot. The dyeing machine capacity is calculated on weight, so it is necessary to maintain the uniform weight throughout the packages. To do this for a definite count of yarn following calculation is followed, In this machine length is pre selected. For different count of yarn different length of yarn is pre selected. This is due to maintain the constant package weight and package density.

  33. Package density Calculation We know package density ρ =mass (m)/volume (v) gm/cc Volume= π (R2-r 2) h R= outer radius of package R= inner radius of package h= height of package Now we consider a sample of 40/1 cotton yarn whose R=4.138 r= 1.59 h=15.24 Mass m=1000gm So package density ρ=1000/π (4.1382-1.592)15.24 gm/cc =1.433 gm/cc Production calculation: We know production= speed (m/min) ×60×24 ×1.09/(840×40×2.2045) Kg/day/head When speed is 800m/min at 80% efficiency Production=800×60×24×1.09/ (840×40×2.2045)kg/day/head =10.5976kg/day/head Total production=10.5976×54×12kg/day =6867.2448kg/day

  34. Production calculation of RF Dryer Production calculation of RF Dryer : Length of RF Dryer = 13m At 28rpm it takes 21 min 9 sec to pass this length Along this length it can accommodate 416 package 416kgs So at 21 min9sec or 1269sec it can dry 416kgs So in 1hr or 3600sec it can dry = 416×3600/1269 kg/hr = 1180.14 kg/hr So Production per day = 1180.14×24kg = 22658.688 kg = 22.66 tons

  35. Knit Dyeing Calculation and Equation

  36. Calculations related to batch section: Now, when a gram per linear meter is low then meters per chamber will be more. Thus, fabric loading should be reduced to avoid jamming in the winch. In this case 80-85% fabric loading is given. But when gram per linear meter is more then rope length will reduce and in this case up to 90% fabric loading can be given.

  37. Calculating the chamber loading In the following table are listed general recommendations covering rope cycle times and speeds for a wide range of fabrics: Fabric Rope cycle times in minutes (Cycle Time) Rope circulation speed m/min (Reel speed) Knit fabric PES unfixed PES heat set PC Co - reactive 1 250 200 250 1-1.5 1-2 2-3 225-275

  38. Stock solution preparation: Preparation and storage of stock dyes and chemicals Available stock solution: 1. 2. 3. Preparation:  To prepare 0.1% stock solution, it necessary to mix 0.1 gm dye with 100cc water.  To prepare 0.5% stock solution, it necessary to mix 0.5 gm dye with 100cc water.  To prepare 1.0% & 2.0% stock solution similar procedure is followed.  To prepare 10% stock solution of soda ash, it necessary to mix 10 gm soda with 100cc water. Red-0.1%, 0.5%, 1%, 2% Yellow-0.1%, 0.5%, 1.0%, 2.0%, Blue- 0.1%, 0.5%, 1.0%, 2.0%. SHADE % STOCK SOLUTION % 0.0001-0.009 0.1 0.10-0.99 0.5 1-1.99 1 2-3.99 2 4 ( or above) 4

  39. Stock Solution Making Procedure (Dyeing lab) For solid, X gm chemicals/dyes/auxiliaries in the 100 ml water is called x% stock solution. For liquid, X ml/cc chemicals/dyes/auxiliaries in the (100 - x ml/cc) water is called x% stock solution. Conversion formula from percentage to g/l is as g/l = Required amount (%)× 10

  40. Recipe Calculation

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