Weaving Calculations FM-4023

Zuhaib Ahmad

Indirect System

Direct System

In this system the count of yarn expresses the

number of length units in one weight unit.
This system is generally used for cotton,
worsted, woolen, linen (wet spun), etc.

In this system the count of yarn expresses the

number of weight units in one length unit.
This system is generally used for silk,
artificial silk, jute, etc.

It may be noted that finer or less bulky the

yarn, higher is its count number or in other
words, the size or bulkiness of the yarn is
inversely proportional to the count number
and that is why the system is known as
indirect system.

=

The size or bulkiness of the yarn is directly

proportional to the count number. A coarser
yarn will have a higher count number while
finer yarn will have a lower count number.
The system is used for very finer or very
coarse yarns.

1. Cotton Count = = 8.33

( )
( )
( )

2. Worsted Count = = 12.5 ( )

( )

3. Woolen Count = = 27.34 ( )

4. Decimal Count = = 7

( )

( )
( )
( )

6. French Count = = 1/2

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

Linen (wet spun)

Spun Silk
Jute, Hemp and Flax
Tex
Denier
D.Tex/Grex
Dram

1 lb.
1 lb.
1 lb.
1 lb.
1 grm.
1 grm.
1 grm.
1 dram = 27.34 grains

Hank of 256 yards.

Leas of 300 yards.
Hank of 840 yards
Hank of 14,400 yards.
Hank of 1000 meters
Hank of 9000 meters
Hank of 10,000 meters
Hank of 1000 yards

1 . = 16 = 7000 = 453.6 , 1 = 28.35

. = 2.2046 , 1 = 1.0936 , 1 = 27.34

Fall 2012

8th Semester

Weaving Calculations FM-4023

Zuhaib Ahmad

1. Show that 1 oz = 28.3 gms.

2. Show that 1 oz/yd2 = 33.9 gm/m2.
3. Show that 1 lb/in2 = 0.06895 bar
4. Show that in indirect system = 8.33

( )

5. Show that in indirect system = 12.5

( )
( )

6. Show that in indirect system = 27.34 ( )

( )

7. Show that in indirect system = 7 ( )

( )

( )

8. Show that in indirect system = ( ) = ( )

( )

9. Show that in indirect system = 1/2 ( )

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

24. Show that in direct system = 27.34

25.
26.
27.
28.
29.
30.
31.

( )

( )
( )
( )

( )
( )

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:

L1 = Length in known system

L2 = Length in required system
W1 = Weight in known system

Fall 2012

8th Semester

Weaving Calculations FM-4023

Zuhaib Ahmad
2
1
2 = 1 [
]
1
2
4. Indirect to Direct:

W2 = Weight in required system

C1 = Count in known system
C2 = Count in required system

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.

Convert 20s cotton into Worsted system.

Convert 30s woolen yarn into Linen count.
Convert 135 denier into Tex count.
Calculate the equivalent count of 163 Tex into Grex system.
Convert 100s cotton into Denier system.
Convert 20 Tex into Worsted count.
Convert 135 Denier into Tex system.

Show that for cotton count =

9.
10.
11.
12.

Show that for cotton count =

Show that = .
Show that = .
Show that for cotton count =

Count of Folded Yarn

The counts of folded yarns in cotton, linen and worsted are expressed in terms of the counts
of the single threads of which the folded yarn is composed. There will be some contraction in
length when two threads are twisted together; so that the actual count of single thread
required producing a twofold yarn of 21 s count will be slightly finer than 42 s. But this
contraction is not significant in ordinary cases.
To calculate the count of folded yarn, assume a definite length unit, say one hank. Then the
weight of such length unit of each component threads is found out. The sum of these weights
will be the weight of the assumed length unit of resultant folded yarn. The length and weight
being known, the count of the folded yarn can be easily calculated by using suitable formula.
For Indirect System

For Direct System

1
1
1
=
+
1 2

= 1 + 2

And for n Yarn Counts

And for n Yarn Counts

1
1
1
1
=
+
+ +
1 2

Fall 2012

= 1 + 2 + +

8th Semester

Weaving Calculations FM-4023

Zuhaib Ahmad

Where;
R1 = Count of 1st individual yarn
R2 = Count of 2nd individual yarn

Note: The counts should be in same system.

RC = Count of resultant yarn.

1. Calculate the counts of 3 fold cotton yarn composed of 20/1, 15/1 and 12/1.
2. One thread of an unknown count, when folded together with another 72/1 cotton yarn gives
a two fold yarn of 31.5 cotton. Calculate the count of unknown thread.
3. A 3-fold cotton yarn is composed of 8s, 24s& a thread of un-known count was found to be a
4s cotton. Calculate the count of unknown thread.
4. Calculate the count of the corkscrew yarn produced by twisting together one thread of 2/40 S
and the other of 10s cotton. By actual measurement it was found that 20 inches of 10 S thread
and 10 inches of 2/40S are contained in 10 inches of corkscrew yarn.
5. A 5S folded yarn is composed of one thread of 25S and another of 10S the latter having the
region of 60%. Calculate the weight of component threads in 100 lbs of folded yarn.

Cost of Folded Yarn

If,

And if,
A= Count of 1st yarn

A= Count of 1st yarn

B= Count of 2nd yarn

B= Count of 2nd yarn

y= Cost of 1st yarn

C= Count of 3rd yarn

z= Cost of 2nd yarn

y = Cost of 1st yarn

z= Cost of 2nd yarn
w= Cost of 3rd yarn

Cost of folded yarn (material) =

+
=
+

Cost of folded yarn (material) =

+ + ()
+ +

Total cost of folded yarn= = + Conversion cost of folding

= +
1) A yarn of 36/1 costs 42Rs/lb & 12/1 yarn costs 14Rs/lb. What is the cost of yarn composed of
two twisted threads?
2) Find the cost of 3 folded yarn composed of 60/1, 40/1 & 20/1 & cost of yarn/lb is 32, 24 &
16Rs/lb respectively. If folding cost is 55Rs/lb.
3) Calculate the cost of 4 ply yarn of 80s, 60s, 50s& 40s yarn. If their cost is 40, 36, 32 & 24
Rs/lb. If folding/conversion cost is 0.85Rs/lb.

Fall 2012

8th Semester

Weaving Calculations FM-4023

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

WC = Conditioned weight of yarn.

%

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

Weaving Calculations FM-4023

Zuhaib Ahmad

This means we have to take 400 hanks of each count.

400 hanks of 80/S weighs=
400 hanks of 50/S weighs=
400 hanks of 40/S weighs=
400 hanks of 20/S weighs=
Now,

( )

( )

( )

( )

400

400

400

400

80

50

40

20

= 5
= 8
= 10
= 20

Total number of hanks = 400+400+400+400=1600 hanks

Total weight= 5+8+10+20=43 lbs

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

Weaving Calculations FM-4023

Zuhaib Ahmad

Where, th = Time in hours

Where,

n= number of spindles

Ne = English Count

Eff.= Machine efficiency for the said

time period in hours

And
% =

=
=

Where, N = R.P.M. of machine

100%

D= Diameter of winding drum

1) How much time will be required to wind 2388lbs of 20 s cotton yarn on 40 drums on winding
machine. If calculated rate of winding is 1298yds/min & efficiency is 80%?
2) How many drums would be require to wind one thousand pounds (1000 lbs) of 24 s cotton
yarn in 12 hours. If actual production per drum per minute is 520 meters.
3) Calculate the no. of days & hours required to wind 60,000lbs of 54 s cotton yarn on 500
winding drums, each of which has calculated rate of winding is 630yds/min. The efficiency
of machine is 90%.
4) Calculate the no. of spindles of winding machine that would be requires to wind 280lbs of 30
Tex cotton yarn in 8hrs if actual production per spindle per hour is 1.4lbs.
5) The rate of winding (calculated) of high speed cone winding machine is 800yds/min.
Calculate the no. of drums that will be require to wind 388lbs of 40/1 cotton yarn from ring
bobbins in 8 hours. Allow 1% waste on bobbin.
6) Calculate the efficiency of winding machine if its production (actual) per 8 hours is found to
be 384 hanks. The rate of winding is 800yds/min.
7) The winding drum of High speed winding machine having dia of 3 makes 2870rpm. The
actual amount of yarn wound in 9 hours was found to be 332838yds. What is the efficiency
of the machine?
8) Calculate the time required to wind 2880hanks of 12/1 cotton yarn with 8 spindles. The rate
of winding is 420/min & efficiency is 75%.
9) The rate of winding is 980yds/min. Calculate the no. of spindles require to wind 3024hanks
of 20s in4 hours, efficiency of machine is 90%.
10) Calculate the no. of drums required to wind 1000kgs of 150 denier cotton yarn in 8 hours
with 625metre/min. If the machine runs with 92% efficiency.

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

Weaving Calculations FM-4023

Zuhaib Ahmad

Where, th = Time in hours

. (/) 60 .
840 100

Eff.= Machine efficiency for the said

time period in hours

Where, Ew= number of Ends of a warped beam

And, % =

Where, N = R.P.M. of machine

D= Diameter of Warping drum

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%.

Proportion of Warping to Sizing

/
/
=
=

/
/

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

Weaving Calculations FM-4023

I.
II.
III.
IV.
V.
VI.
VII.

Zuhaib Ahmad

Number of warp beams

Number of Ends/Warp beam
Length of warp/Warp beam
Weight of warp/ warp beam
Total weight of warp yarn
Number of bags, if cone remainder is 1.5%
Calculate pounds/break if number of breaks are 8.

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

Length of warp/back beam =

= [ / . ] +

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

Weaving Calculations FM-4023

/ =

Zuhaib Ahmad

.
840 .
=

/10 =

33550 1.0936 640

= 118.3
840 29.53 8

/ 107
.
=

118.33 107
= 4.59
33550 7680

Sizing Calculation
= (/) 60
=

(/) 60 .
100

(/) 60
840

(/) 60 .
840 100

+
/

. =

+
/

Size %age
% =

100

S%=Size %age

=Weight of size material

100
100 + %
()
=
840
()
=
840

=Weight of warp yarn

Fall 2012

=Length of sized warp

=Weight of sized yarn
=Count of sized yarn

10

8th Semester

Weaving Calculations FM-4023

Zuhaib Ahmad

Size solution calculation

% =

.
100
.

%= Concentration

. ()(100 )
. ()
. ()(100 )
. =
100

. = Solid content in kg

% =

. = Size solution in kg or liter

. =Size material in kgs

. = + . + (. ( )

= . . (. ( )

. 100

=
(. ( )
100 + .

(%) (%)
100
( ) %
() =
100
(%) ( )
. . =
100
() 100
% =
()
% =

= Specific volume of sized

material
=Water in liters
C.A= Condensation Allowance

% = Size solution absorption of size

pickup %age
% = Degree of sizing
. . = Size solution requirement
= Volume of size solution

Size width (mm)

Y (l/cm)

1800

5.8

2000

6.4

2200

7.0

2400

7.6

2600

8.2
= (

Fall 2012

=Water content of sized

material

11

8th Semester

Weaving Calculations FM-4023

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

Weaving Calculations FM-4023

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