RAW MATERIAL CALCULATIONS

Introduction
In calculations of cloth, important calculations which are
often required to be done 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.
To find the amount of materials required, 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 of are:

Contraction of Weft and Weft

Count of Yarn
No. of intersections
Nature of Weave/ Repeat
Reed Count

Quantity of Material
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

Example 1
Grey and Mono-coloured Plain Fabric
A cloth 44.5 inches wide on a 72s Stockport reed is woven with 32s Warp
and 40s Weft and 64 picks per inch. Selvedges 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

inch each

Reed Count

72s Stockport

Selvedge Denting

4:4

Warp Count

32s

Selvedge Yarn Count

Same as Warp Count

Weft Count

40s

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

inch each

Reed Count

84s Stockport

Selvedge Denting

4:4

Cloth Width

40.5 inch

Selvedge Yarn Count

2/42s Bleached Cotton

Weft Count

50s

Length of piece

30 Yards

PPI

72

Warp Crimp/ Regain

4%

Repeat Pattern for Warp

40s Dark Brown

3 Ends

36s White

3 Ends

32s Green Printed

1 Ends

36s White

3 Ends

36s Light Brown

5 Ends

2/50s Grandrelle (Dark Yellow & White)

1 Ends

36s 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 40s Dark Brown Ends

3 Ends

3*160 = 480

Total No. of 36s White Ends

6 Ends

6* 160 = 960

Total No. of 32s Green Printed Ends 1 Ends

1*160 = 160

Total No. of 36s Light Brown Ends

10 Ends

10*160 = 1600

Total No. of 2/50s Grandrelle (Dark

Yellow & White) Ends

1 Ends

1*160 = 160

Sol:

(b) Length of Warp Yarns

Total length of 40s Dark Brown Ends

3 Ends

3*160 = 480

480*31.2/840 = 17.9 Hks

Total length of 36s White Ends

6 Ends

6* 160 = 960

960*31.2/840 = 35.7 Hks

Total length of 32s Green Printed Ends

1 Ends

1*160 = 160

160*31.2/840 = 5.95 Hks

Total length of 36s Light Brown Ends

10 Ends

10*160 = 1600

1600*31.2/840 = 59.5 Hks

Total length of 2/50s Grandrelle (Dark

Yellow & White) Ends

1 Ends

1*160 = 160

160*31.2/840 = 5.95 Hks

Total length of 2/42s Bleached Selvedge

Ends

84 Ends

84*31.2/840 = 3.12 Hks

(c) Weight of Yarns

Total length of 40s Dark Brown Ends

480*31.2/840 = 17.9 Hks

17.9/40 = 0.446 lbs

Total length of 36s White Ends

960*31.2/840 = 35.7 Hks

35.7/36 = 0.992 lbs

Total length of 32s Green Printed Ends

160*31.2/840 = 5.95 Hks

5.95/32 = 0.186 lbs

Total length of 36s Light Brown Ends

1600*31.2/840 = 59.5 Hks 59.5/36 = 1.653 lbs

Total length of 2/50s Grandrelle Ends

160*31.2/840 = 5.95 Hks

5.95/25 = 0.238 lbs

Total length of 2/42s Bleached Selv Ends

84*31.2/840 = 3.12 Hks

3.12/21 = 0.148 lbs

Total Weight of Warp Yarns

Total Weight of Weft Yarns
(d) Total weight

3.663 lbs
30*72*40.5/(840*50)

2.083 lbs
5.746 lbs

Example 3
A cotton cloth has 80 ends and 80 picks per inch. The counts of warp and weft
are 60s and 80s respectively. There is selvedge with 4 ends drawn per
dent on each side. If the width of the cloth is 40 inches, what is the weight of
40 yards of such a cloth? Also calculate the weight of warp and weft that
would be required to produce 10,000 yards of the cloth. Make your own
estimate for all allowances to be made for warp and weft take-up

Example 4
A bleached cotton with 64 ends and 56 picks per inch is 80 yards long. The
tape length of warp from which it has been produced is 85 yards. The counts
of warp and weft are 32s and 42s respectively. The width of the cloth is 48
inches with 3 inches border on each side. The border ends are 2/42s dyed
cotton in dark blue colour and drawn 4 ends per dent. What is the weight of
12,000 yards of such a cloth? Also calculate the weight of warp and weft.
Make your own estimate for all allowances to be made.

Example 5
Ascertain the total amount of warp and weft in a piece of cloth 10 yards long.
The cloth has 72 ends and 80 picks per inch. The counts of warp and weft are
28s and 40s respectively. There is selvedge with 4 ends drawn per dent
on each side. The width of the cloth is 40 inches.

Example 6
The warp pattern of a stripe cloth is as follows:
32s Dark Blue
12 ends
30s White
08 ends
32s Light Blue
02 ends
30s White
08 ends
The cloth is 28.5 inches wide and 40 yards long on a 76s Stockport Reed and the
tape length of warp used for the cloth is 42.5 yards. The no. of picks per inch in
the cloth is 72. The count of weft is 40s cotton. There is selvedge with 4 ends
drawn per dent on each side. The selvedge ends are 2/42s dyed cotton in dark
blue colour. What is the weight each coloured yarn of warp and weft.

Answers
Example 3:

Example 4:

Example 5:
Example 6:

Weight of warp for 40 yards = 2.54 lbs

Weight of weft for 40 Yards = 1.90 lbs
Weight of yarns for 10,000 Yds = 1111.11 lbs
Weight of warp for 12,000 Yds = 1552.55 lbs
Weight of weft for 12,000 Yds = 914.29 lbs
Weight of yarns for 12,000 Yds = 2466.84 lbs
Weight of warp = 1.225 lbs
Weight of weft = 0.952 lbs
Weight of 32s Dark Blue = 0.531 lbs
Weight of 30s White = 0.756 lbs
Weight of 32s Light Blue = 0.089 lbs
Weight of Selvedge Warps = 0.183 lbs
Weight of Weft =2.442 lbs