PRODUCTION CALCULATION IN

SPINNING MILLS

J.Sreenivasan
Liaison and consultation division
SITRA
 SEQUENCE OF MACHINERY
CARDED COUNTS COMBED COUNTS

Blow room Blow room Blow room

Cards Cards Cards

Pre comber Sliver lap

draw frame
Breaker
draw frame Unilap /Lap former Ribbon lap

Comber Comber
Finisher
Post comber Draw frame
draw frame
draw frame

Fly frame Fly frame Fly frame

Ring frame Ring frame Ring frame

 YARN NUMBERING SYSTEM

Yarn numbering system

Direct system In direct system

Tex Denier English Metric French

(T) (D) count count count
(Ne) (Nm) (Nf)
 YARN NUMBERING – DIRECT SYSTEM
In this system, unit length is taken as fixed and its weight
is measured
Tex (T) - Weight in grams/ Length in 1000 m
Denier (D) - Weight in grams/ Length in 9000 m
Example:-
40 Tex :- A length of 1000 meter gives 40 grams of
weight
120 Denier :- A length of 9000 meter gives 120 grams of
weight
In this system, yarn becomes coarser / heavier as the count
number increases
 YARN NUMBERING – INDIRECT SYSTEM
In this system, unit weight is taken as fixed and its length is
measured
English (Ne) - Length in hanks of 840 yards
Weight in 1 pound
Metric (Nm) - Length in km / weight in 1000 g
French (Nf) - Length in km / weight in 500 g
Example:-
Ne 5 :- In one pound of yarn weight there are 4200 (840 x 5)
yards of yarn length.
In this system, the yarn becomes finer as the count number
increases.
 YARN NUMBERING SYSTEM
DIRECT SYSTEM
Tex (T) - Weight in grams/ Length in 1000 m
Denier (D) - Weight in grams/ Length in 9000 m

INDIRECT SYSTEM
English (Ne) - Length in hanks of 840 yards
Weight in 1 pound
Metric (Nm) - Length in km/ weight in 1000 g

French (Nf) - Length in km/ weight in 500 g

 COUNT CONVERSION FACTORS

Ne - Nm / 1.69
Ne - 590.5 / T
Ne - 5315 / D
T- D / 9
Nm - 2 x Nf

Ne – English count; Nm – Metric count

Nf – French count; T – Tex; D – Deniar
 COUNT CONVERSION CALCULATIONS

Calculate the following

1.Convert Tex 40 to English count (Ne) ?

Answer :- Ne = 590.5 / 40 = 14.8

1.Convert Nf 40 to English count (Ne)?

Answer :- Nm = 2 x Nf = 2 x 40 = 80
Ne = Nm / 1.69
= 47.33
 COUNT CONVERSION CALCULATIONS

Calculate the following

3. Convert Ne 50 in to Tex, Denier, and metric
count?
Answer:-

Tex = 590.5 / Ne = 590.5 / 50 = 11.8

Denier = 5315 / Ne = 5315 / 50 = 106.3

Nm = 1.69 x Ne = 1.69 x 50 = 84.5

CONVERSION UNITS - BASICS

1 metre = 1.094 yards

1 yard = 0.914 m
1 yard = 36 inches
1 lea = 120 yards
1 hank = 840 yards
1 kg = 2.205 pounds
1 pound = 453.6 g
 CONVERSION UNITS - BASICS

Length in Weight in
= 1.693 x Count (Ne) x
metres grams

Weight in grams 0.59

= x Length in
Count (Ne) metres

Count of yarn 64.8

from lea (Ne) =
Lea weight in grams
WRAP REEL
 BASIC CALCULATIONS

Calculate the following

1. Calculate the length of yarn in the package of
2500 gm of Ne: 40s?
Answer:-

Length in meter = 1.693 x 40 x 2500

= 169300 mtr
 BASIC CALCULATIONS

Calculate the following

2. Calculate the weight of yarn in the Ne: 20s
package containing length of yarn about 84745 mtr ?

Answer:-

Weight in grams = (0.59/20) x 84745

= 2500 gm
 BASIC DEFINITIONS

Surface Front Speed of the roller in

= x roller x
speed rpm
dia.
(inches)
Length in hanks of 840 yards
Count (Ne) =
Weight in pounds

0.59
ie. =
Weight in grams/metre
 BASIC DEFINITIONS

Hank of delivery material

Draft =
Hank of feed material

Actual production x 100

Efficiency (%) =
Calculated production
BLOWROOM
BLOWROOM
 BLOWROOM

The main objective of blow room is

1.Opening

1.Cleaning

1.Dust removal

1.Blending / mixing

1.Even material fed to subsequent process

(Card)
BLOWROOM LAP
 BLOW ROOM PRODUCTION CALCULATION

Delivery
speed
Production per
(mpm) x 60 x 8 x 1.094 Eff (%)
scutcher per 8 = x
hours (kg) Lap hank 100
x 840 x 2.205
(Ne)

Delivery speed
0.2835 x (mpm) Eff (%)
ie. = x
Lap hank (Ne) 100
 BLOW ROOM PRODUCTION CALCULATION

Delivery speed = 8.5 mpm

Lap hank = 0.0014
Machine efficiency = 85%

Calculate the blow room production per

scutcher per 8 hours ?

Production per 0.2835 x 8.5 85

scutcher per 8 = x
hours (kg) 0.0014 100

= 1463.0 kg per 8 hours

CARDING
 CARDING

The main objective of carding process is

1.Open the flocks into individual fibers

1.Cleaning and elimination of impurities

1.Removal of neps

1.Formation of sliver
 CARDING PRODUCTION CALCULATION

Delivery
speed
Production per
(mpm) x 60 x 8 x 1.094 Eff (%)
machine per 8 = x
hours (kg) sliver hank x 840 x 2.205 100
(Ne)

Delivery speed
0.2835 x (mpm) Eff (%)
ie. = x
Sliver hank (Ne) 100
 CARD PRODUCTION FROM DOFFER SPEED
doffer
doffer speed Tension
Production per x dia (”) x (rpm) x draft
card per 8 hours=
(kg) Sliver hank (Ne) x 36 x 840
60 x 8 Eff (%)
x x
2.205 100
For 27” doffer dia:

Doffer speed (rpm) Tension Eff (%)

ie. = 0.61 x x x
Sliver hank (Ne) draft 100
DRAW FRAME
 DRAWFRAME

The main objective of draw frame process is

1.Doubling of slivers

1.Parallelization of fibers

1.Blending

1.Small dust removal

1.Removal of hooked fibres

 DRAW FRAME PRODUCTION CALCULATION

Delivery
speed
Production per
(mpm) x 60 x 8 x 1.094 Eff (%)
delivery per 8 = x
hours (kg) sliver hank x 840 x 2.205 100
(Ne)

Delivery speed
0.2835 x (mpm) Eff (%)
ie. = x
Sliver hank (Ne) 100
 DRAW FRAME – HANK METER PRODUCTION

Production Surface speed

per delivery of front roller 60 x 8 x 1.094 Eff (%)
= (mpm) x x
per 8 hours 840 100
(hanks)

Surface speed
Eff (%)
ie. = 0.6251 x of front roller x
(mpm) 100
DRAW FRAME PRODUCTION CALCULATION

Delivery speed (mpm) = 450

Sliver hank (Ne) = 0.120

Efficiency = 73.5%

Calculate the prodn. per delivery per 8 hours in kg ?

Answer : 781 kg per delivery per 8 hours

FLYFRAME
FLYFRAME
 FLY FRAME / SIMPLEX
The main objective of fly frame process is

1.Attenuation of drawn sliver to form roving of

required count by drafting

1.Insert a small amount of twist to give required

strength of roving

1.Wind the twisted roving on to the bobbin

1.Build the roving bobbin such a form which will

facilitate handling, withdrawing and transfer to the
next process
 FLY FRAMES

Production /spindle /8 hours (kg)

Spindle speed (rpm) 60 x 8 Eff (%)

= x x
TPI x Roving hank (Ne) 36 x 840 x 2.205 100

7.2 Spindle speed (rpm) Eff (%)

ie. = x x
1000 TPI x Roving hank (Ne) 100

where, TPI = TM x V roving hank

 FLYFRAME PRODUCTION CALCULATION

Spindle speed (rpm) = 950

Twist per inch (TPI) = 1.39
Roving hank (Ne) = 0.80
Machine efficiency % = 82
Number of spindles per machine =120

Calculate the production

per spindle per 8 hours in kg ?

Answer : 5.04 kg per spindle per 8 hours

 FLYFRAME PRODUCTION CALCULATION

Spindle speed (rpm) = 850

Twist per inch (TPI) = 1.15
Roving hank (Ne) = 0.70
Machine efficiency % = 82
Number of spindles per machine =120

Calculate the production per machine

per 8 hours in kg ?
Answer :
748.0 kg per machine per 8 hours
6.23 kg per spindle per 8 hours
RING FRAME
RING FRAME
 RING FRAME
The main objective of ring frame is

1.To draft the roving fed to the ring spinning frame i.

e., to convert roving into very fine strand called yarn.

1.To impart strength to yarn by inserting the

necessary amount of twist

1.To wind the twisted strand of yarn on a bobbin or

tube (handy and transportable package)
 RING FRAMES

Production /spindle /8 hours (g)

Spindle speed (rpm) 60 x 8 x 1000 Eff (%)

= x x
TPI x Yarn count (Ne) 36 x 840 x 2.205 100

Spindle speed (rpm) Eff (%)

ie. = 7.2 x x
TPI x Yarn count (Ne) 100

where, TPI = TM x V yarn count

 RINGFRAME PRODUCTION CALCULATION

Spindle speed (rpm) = 18000

Yarn count (Ne) = 40.0
Twist per inch (TPI) = 27.5
Machine efficiency % = 93.5
Number of spindles per machine =1200

Calculate the production

per spindle per 8 hours in grams ?

Answer : 110 grams per spindle per 8 hours

 RINGFRAME PRODUCTION CALCULATION

Spindle speed (rpm) = 17000

Yarn count (Ne) = 30.0
Twist per inch (TPI) = 23.8
Machine efficiency % = 93.0
Number of spindles per machine =1200

Calculate the production

per machine per 8 hours in kg ?

Answer :
159 g per spindle per 8 hours
191 kg per machine per 8 hours
 FLY FRAMES/ RING FRAMES
PRODUCTION IN HANKS
Production /spindle /8 hours (hanks)
1 Spindle speed (rpm) Eff (%)
= x x
63 TPI 100

HANK TO KG CONVERSION(expected)
No. of
Production No of hanks spindles
= 0.455 x x
per doff (kg) Yarn count (or) per frame
roving hank
LAPFORMER / UNILAP
 SLIVER LAP, RIBBON LAP & LAP FORMER
Lap
Production Surface weight
per machine speed of (g/m)Eff (%)
= x 60 x 8 x x
per 8 hours lap roll 1000 100
(kg) (mpm)
(or)

Delivery speed
0.2835 x (mpm) Eff (%)
ie. = x
Lap hank (Ne) 100
 UNILAP PRODUCTION CALCULATION

Delivery speed (mpm) = 120

Lap weight in grams per meter= 65

Efficiency = 75%

Calculate the production per machine per 8 hours in

kg ?

Answer : 2808 kg per delivery per 8 hours

COMBER
 COMBER

The main objective of comber process is

1.To remove short fibers (Noil)

1.To remove remaining impurities in the lap

1.To remove of neps

1.To produce sliver with more uniformity

 COMBERS
Production L F (100 – w)
480
/comber /8 = S x x x x
hours (kg) TD 1000 1000 100
Eff (%)
x X No.of heads(8)
100
Eff (%) (100 – w)
ie. = 0.0035 x S x L x F x x
100 100
S – Speed in nips/min; L – Lap weight in g/m
F – Feed nip in mpm; w – Noil extracted
TD – Lap tension draft (1.10)
 COMBER PRODUCTION CALCULATION

Comber speed (nips per minute) = 400

Feed per nip (mm) = 4.7
Lap weight (grams per meter) = 70
Machine efficiency % = 90
Noil % = 18%

Calculate the production

per comber per 8 hours in kg ?

Answer : 340 kg per comber per 8 hours

 CONE WINDING
The main objective of cone winding process are

1.To eliminate yarn faults such as long thick places,

long thin places, short thick places, short thin
places, etc.,

1.To wind continuous length of yarns on cones for

downstream process (weaving / knitting)

1.Size and shape of the package should be proper,

so that it can be unwound easily.
 CONE WINDING

Cone winding

Manual cone Automatic cone

winding winding
MANUAL CONE WINDING
AUTOMATIC CONE WINDING
AUTOMATIC CONE WINDING
 CONE WINDING

Production Drum speed

per drum per (mpm) x 60 x 8 x 1.094 Eff (%)
8 hours (kg) = x
Count (Ne) x 840 x 2.205 100

Delivery speed of
0.2835 x drum (mpm) Eff (%)
ie. = x
Yarn count (Ne) 100
 CONE WINDING CALCULATION

Delivery speed drum (mpm) = 1300

Yarn count (Ne) = 50.0

Efficiency = 75%

Number of drums per machine = 60

Calculate the production per drum

per 8 hours in kg ?

Answer : 5.52 kg per drum per 8 hours

 CONE WINDING CALCULATION

Delivery speed drum (mpm) = 1300

Yarn count (Ne) = 30.0
Efficiency = 70%
Number of drums per machine = 60

Calculate the production per machine

per 8 hours in kg ?

Answer :
516 Kg per machine per 8 hours
5.52 kg per drum per 8 hours
TWO-FOR-ONE TWISTER (TFO)
TWO-FOR-ONE TWISTER (TFO)
 TWO-FOR-ONE TWISTER

Production /spindle /8 hours (g)

2 x Spindle speed (rpm) 60 x 8 x 1000 Eff (%)

= x x
TPI x Actual count (Ne) 36 x 840 x 2.205 100

Spindle speed (rpm) Eff (%)

ie. = 14.4 x x
TPI x Actual count (Ne) 100

where, TPI = TM x V yarn count

 TWO-FOR ONE TWISTER CALCULATION

Spindle speed (rpm) = 10000

Yarn count (Ne) = 2/30
Efficiency = 95%
Twist per inch (TPI) = 16.0

Calculate the production per spindle

per 8 hours in g ?

Answer :
570 g per spindle per 8 hours
RING DOUBLING
 RING DOUBLING

Production /spindle /8 hours (g)

Spindle speed (rpm) 60 x 8 x 1000 Eff (%)

= x x
TPI x Actual count (Ne) 36 x 840 x 2.205 100

Spindle speed (rpm) Eff (%)

ie. = 7.2 x x
TPI x Actual count (Ne) 100

where, TPI = TM x V yarn count

 RING DOUBLING CALCULATION

Spindle speed (rpm) = 10000

Yarn count (Ne) = 2/40
Efficiency = 96%
Twist per inch (TPI) = 19.3

Calculate the production per machine

per 8 hours in g ?

Answer :
179 g per spindle per 8 hours
 RING DOUBLING CALCULATION

Spindle speed (rpm) = 11500

Yarn count (Ne) = 2/120
Efficiency = 97.5%
Twist per inch (TPI) = 30.7

Calculate the production per machine

per 8 hours in g ?

Answer :
44 g per spindle per 8 hours
 RING DOUBLING CALCULATION

Spindle speed (rpm) = 11500

Yarn count (Ne) = 2/120
Efficiency = 97.5%
Twist per inch (TPI) = 30.7

Calculate the production per machine

per 8 hours in g ?

Answer :
44 g per spindle per 8 hours
 REELING

Production per reel per 840 yard (kg)

(for 840 yard hank)
18.144 x No. of doffs
For SHPR =
Yarn count (Ne)

For DHPR 18.144 x No. of doffs x 2

=
(or) DHCR Yarn count (Ne)

Note: In case of 1000 metre hank, multiply the figures from

the above formula by 1.3
 SPIN PLAN

Calculate a spin plan for a 12000 spindle

mill

manufacturing Ne: 40s carded yarn.

 SPIN PLAN – RING FRAME PRODUCTION
Data required:
Actual count (Ne) :
Average spindle speed (rpm) :
Twist per inch :
Machine efficiency (%) :
Total number of spindles :
Number of spindles per ring frame :

To calculate:
Total number of ring frames :
Production per spindle per 8 hours (g) :
Production per day @ 100% SU (kg) :
 REQUIREMENT OF FLYFRAME
Data required:
Production required in fly frame (kg) :
Actual hank (Ne) :
Average spindle speed (rpm) :
Twist per inch :
Machine efficiency (%) :

To calculate:
Production per spindle per 8 hours (kg) :
Production per spindle per day (kg) :
Number of spindles required :
Number of machines required :
Number of machines to be allotted :
 REQUIREMENT OF FINISHER DRAWFRAME

Data required:
Production required in draw frame (kg) :
Actual hank (Ne) :
Delivery speed (mpm) :
Machine efficiency (%) :

To calculate:
Production per delivery per 8 hours (kg) :
Production per machine per day (kg) :
Number of machines required :
Number of machines to be allotted :
 REQUIREMENT OF BREAKER DRAWFRAME

Data required:
Production required in draw frame (kg) :
Actual hank (Ne) :
Delivery speed (mpm) :
Machine efficiency (%) :

To calculate:
Production per delivery per 8 hours (kg) :
Production per delivery per day (kg) :
Number of delivery required :
Number of machines required :
Number of machines to be alloted :
 CARDING REQUIREMENT

Data required:
Production required in cards (kg) :
Actual hank (Ne) :
Delivery speed (mpm) :
Machine efficiency (%) :

To calculate:
Production per card per 8 hours (kg) :
Production per card per day (kg) :
Number of cards required :
Number of cards to be alloted :
 DRUMS REQUIRED IN CONE WINDING PROCESS

Data required:
Drum speed (mpm) :
Actual hank (Ne) :
Machine efficiency (%):

To calculate:
Production per drum per 8 hours (kg):
Production per drum per day (kg) :
Number of drums required :
Number of machines required :
 SPIN PLAN

Calculate a spin plan for a 30000 spindle

mill

manufacturing Ne: 50s carded yarn.

Process parameters for calculating spin
plan
Department : Ring frame
Process parameters Value
Actual count (Ne) 50.0
Average spindle speed (rpm) 18000
Twist per inch 30.41
Machine efficiency % 94.0
Total number of spindles 30000
Number of spindles per ring frame 1200
Waste received in ring frame % 2.0
Process parameters for calculating spin
plan
Department : Fly frame
Process parameters Value
Actual hank (Ne) 1.55
Average spindle speed (rpm) 1100
Twist per inch 1.56
Machine efficiency % 86.5
Waste received in fly frame % 0.5
 MIXING REQUIREMENT

To calculate

Production required from blowroom (kg) :

Rawmaterial required for mixing per day (kg) :

Process parameters for calculating spin
plan
Department : Finisher draw
frame
Process parameters Value
Actual hank (Ne) 0.140
Delivery speed (mpm) 450
Machine efficiency % 80.0
Waste received in finisher draw frame % 0.3
Process parameters for calculating spin
plan
Department : Breaker draw frame
Process parameters Value
Actual hank (Ne) 0.140
Delivery speed (mpm) 400
Machine efficiency % 77.5
Waste received in breaker draw frame % 0.3
Process parameters for calculating spin
plan
Department : Carding
Process parameters Value
Actual hank (Ne) 0.140
Delivery speed (mpm) 130
Machine efficiency % 95
Waste received in card % 4.5
Process parameters for calculating spin
plan
Department : Cone winding
Process parameters Value
Actual count (Ne) 50.0
Drum speed (mpm) 1300
Machine efficiency % 75.0
 SPIN PLAN

Calculate a spin plan for a 12000 spindle

mill

manufacturing Ne: 40s combed yarn.

Process parameters for calculating spin
plan
Department : Mixing
Process parameters Value
Waste received in blow room% 2.0
Thank you