Formula for Spin Plan and Weave Plan

Formula for Spin Plan and Weave Plan
Shubham Dadaso Patil
Dkte’s Textile & Engineering Institute, Ichalkaranji, India
Email: shubhampatil941996@gmail.com



Introduction:
As we know textile is a traditional process. Production planning and control is very important factor in case of textiles, as it requires high production with more profit, less expenditure and with minimization of wastage. Inventory control is another fact that has to be performed well for proper inventory i.e. raw material and finished product, so that the market demand will be fulfilled easily. Hence for achieving proper production planning and control (PPC) we should be familiar to some basic formulae of spinning and weaving production.

Weave plan
Fig: Weave plan
A.FORMULAE FOR SPIN PLAN:

                                                                                rpm x 60 x 8 x 3 x efficiency%
1. RINGFRAME PRODUCTION (KG/SPINDLE/DAY) = ------------------------------------------------------
                                                                                TPI x 36 x 840 x Ne x 2.2 x 100

                                                                                Target production (kg)
No. of spindles required for Target production = -----------------------------------------------------
                                                                              Production per spindle (kg)

                                                               Total No. Of Spindles Required
No. of Ringframe machines required = --------------------------------------------------------
                                                                No. Of Spindles per Machine

Production Requirement from Speedframe = Target Production + Waste% at Ringframe

                                                                             Rpm x 60 x 8 x 3 x efficiency%
2. SPEEDRAME PRODUCTION (kg/spindle/day) = -----------------------------------------------------
                                                                             TPI x 36 x 840 x Ne x 2.2 x 100

                                                                            Production Required from Speed Frame (kg)
No. of spindles required for Target production = ---------------------------------------------------------------
                                                                                        Production per spindle (kg)

                                                                  Target No. of Spindles Required
No. of Speedframe machines required = -----------------------------------------------------------
                                                                     No. Of Spindles per Machine

Production Requirement from Drawframe = Production Requirement from Speedframe + Waste% at Speedframe

                                                                                              rpm x1.1 x 60 x 8 x 3 x efficiency%
3. FINISHER DRAWFRAME PRODUCTION (kg/machine/day) = ---------------------------------------------------
                                                                                                      840 x Ne x 2.2 x 100

                                                                              Production Required from Drawframe (kg)
No. of Machines required for Target production = ---------------------------------------------------------------------
                                                                                      Production per Drawframe (kg)

Production Requirement from Comber = Production Requirement from Drawframe + Waste% at Drawframe

4. COMBER PRODUCTION (kg/machine/day), 

 
  Feed per nip (mm) x NPM x 60 x 8 x 3 x efficiency % x (100- W %) x Lap wt. (g / m) x no. of heads
= --------------------------------------------------------------------------------------------------------------------------------------------
                                                         1000 x1000 x100 x 100

                                                                               Production Required from Comber (kg)
No. of Machines required for Target production = ----------------------------------------------------------
                                                                                      Production per Comber (kg)

Production Requirement from Comber Preparatory = Production Requirement from Comber + Waste% at Comber

5. COMBER PREPARATORY PRODUCTION (kg/machine/day),

   mpm x1.1 x 60 x 8 x 3 x efficiency%
= ------------------------------------------------------
             840 x Ne x 2.2 x 100

                                                                         Production Required from Comber Preparatory (kg)
No. of Machines required for Target production = -------------------------------------------------------------------
                                                                                  Production per Comber Preparatory (kg)

Production Requirement from Breaker Drawframe = Production Requirement from Comber Preparatory + Waste% at Comber Preparatory


6. BREAKER DRAWFRAME PRODUCTION (kg/machine/day),

     mpm x1.1 x 60 x 8 x 3 x efficiency%
= --------------------------------------------------------
               840 x Ne x 2.2 x 100

                                                                             Production Required from Breaker Drawframe (kg)
No. of Machines required for Target production---------------------------------------------------------------------
                                                                                       Production per Breaker Drawframe (kg)

Production Requirement from Carding = Production Requirement from Breaker Drawframe + Waste% at Breaker Drawframe

7. CARDING PRODUCTION (kg/machine/day),

    mpm x1.1 x 60 x 8 x 3 x efficiency%
= --------------------------------------------------
             840 x Ne x 2.2 x 100

                                                                               Production Required from Carding (kg)
No. of Machines required for Target Production = ----------------------------------------------------------
                                                                                        Production per Card (kg)

Production Requirement from Blowroom = Production Requirement from Carding + Waste% at Breaker Carding

                                                                                Production (kg/hr) x 60 x 8 x 3 x efficiency%
8. BLOWROOM PRODUCTION (kg/machine/day)---------------------------------------------------------------
                                                                                                             100

                                                                             Production Required from Blowroom (kg)
No. of Machines required for Target production = -----------------------------------------------------------------
                                                                                  Production per Blowroom (kg)


9. SOME STANDARDS FOR SPIN PLAN CALCULATION:

DEPARTMENT
COUNT
SPEED
WASTE %
EFFICIENCY %
TM
Ringframe
10s-100s Ne
13000-22000 rpm
3.5
90-99
3.5-5.5
Speedframe
0.8-3
1200-1800 rpm
0.5
85-88
1-1.3
Post Drawframe
0.10-0.22
600-800 mpm
0.25
85-88
-
Breaker Drawframe
0.10-0.22
800-1000 mpm
0.25
86-88
-
Comber
0.10-0.22
250-400 NPM
10-22
86-88
-
Comber Preparatory
0.010-0.022
60-110 mpm
0.25
84-88
-
Card
0.10-0.22
200-400 mpm
3.5-4
84-88
-
Blowroom
-
800-1200 kg/hour
3.5-4
80-84
-

NOTE:

A. Depending upon Requirement changes can be done in above given values.

e.g. For Production Of Combed Hosiery Yarn:

  • TM of Ringframe Is reduced by 20 %
  • 20 % Extra Spindles Is Taken In Ringframe
  • 20 % Extra Carding Machines Are Taken
B. Count of card sliver = count of breaker drawframe = count of finisher drawframe

C. For producing 100 % synthetic yarn following considerations should be made:

  • Blowroom & Card Waste = 1 %
  • Waste At All Other Machines = 2 %
  • Speed Of All Machines Should Be Kept 20 % Less Corresponding To Speeds Given In Table Above
B. FORMULAE FOR WEAVE PLAN:

                                                                              Rpm x 60 x 8 x 3 x efficiency%
1. PRODUCTION OF LOOM (mtrs/day/machine) = ----------------------------------------------------
                                                                                         PPI x 39.37 x 100

                                                Target Production (mtrs/day)
No. Of Looms Required = -----------------------------------------------------------------
                                              Production per loom (mtrs/day)

2. WEIGHT OF WARP (g/m),

 
   Total No. of Ends x 1.0937 x (1+warp crimp %/100) x1000
= ----------------------------------------------------------------------------------------------------
                         840 x 2.202 x warp Count

   EPI x Width (inches) x 1.0937 x (1 + warp crimp % / 100) x 1000
= ----------------------------------------------------------------------------------------------------
                              840 x 2.202 x warp Count

3. WEIGHT OF WEFT (g/m),


    Total No. of Picks x 1.0937 x (1 + weft crimp % / 100) x 1000
= -----------------------------------------------------------------------------------------------
                              840 x 2.202 x weft Count

   PPI x Width (inches) x 1.0937 x (1 + weft crimp % / 100) x 1000
= --------------------------------------------------------------------------------------------------
                           840 x 2.202 x weft Count

4. TOTAL WARP REQUIRED FROM SIZING (kg/day),

   (Warp weight (g/m) x target production)
= ---------------------------------------------------------- x Warp waste % at loom shed
                            1000

5. PRODUCTION OF SIZING (kg/day),

   EPI x Width (inches) x mpm x 1.0937 x 60 x 8 x 3 x efficiency %
= -------------------------------------------------------------------------------------------------
                             840 x 2.202 x warp Count x 100

                                                            Production required from sizing (kg/ day)
No. Of Sizing Machines Required = -----------------------------------------------------------------------
                                                            Production per Sizing Machine (kg/ day)

Production Required From Warping = Requirement from Sizing + Waste % at Sizing

6. PRODUCTION OF WARPING (kg/day),

  Ends per beam x mpm x 1.0937 x 60 x 8 x 3 x efficiency %
= ------------------------------------------------------------------------------------------------
                  840 x 2.202 x warp Count x 100

                                         Total No. of Ends
No. Of Warper Beam = ---------------------------------------
                                           Creel Capacity

                             Total No. of Ends
Ends Per Beam = ----------------------
                                No. of Beam

                                                                     Requirement from Warping
No. Of Warping Machines Required = --------------------------------------------------------------------
                                                           Production per Machine (kg/ machine/ day)

Production Required From Winding = Requirement of Warping + Waste % at Warping

7. PRODUCTION OF WINDING (kg/drum/day),

   No. of Ends x mpm x 1.0937 x 60 x 8 x 3 x efficiency %
= --------------------------------------------------------------------------------------------
                      840 x 2.202 x warp Count x 100

                                                               Requirement from Winding
No. Of Drums Required for Warp = --------------------------------------------------------------
                                                           Production of winding drum (kg/ day)

8. Total Weft Required From Winding (kg/day),

  (Weft weight (g/m) x target production)
= ------------------------------------------------------- x Weft waste % at loom shed
                               1000

9. PRODUCTION OF WINDING (kg/drum/day),

   No. of Ends x mpm x 1.0937 x 60 x 8 x 3 x efficiency %
= ----------------------------------------------------------------------------------------------
                   840 x 2.202 x weft Count x 100

                                                             Requirement from Winding
No. Of Drums Required for Weft = --------------------------------------------------------------
                                                      Production of winding drum (kg/ day)

Total Drums Required = Drums Required For Warp + Drums Required For Weft

                                                                   Total Winding Drums Required
No. Of Winding Machines Required = ------------------------------------------------------------------------
                                                                  No. of drums per winding machine


10. SOME GENERAL CONSIDERATIONS FOR WEAVE PLAN:

Department
Speed
Waste %
Efficiency %
Loom
Depends on type of machine used
0.5-1
80-85
Sizing
40-45 mpm
1
45-50
Warping
250-300 mpm
1
15-18 (sectional warping)
Winding
800-1000 mpm
0.5
75-80
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Mazharul Islam Kiron is a textile consultant and researcher on online business promotion. He is working with one European textile machinery company as a country agent. He is also a contributor of Wikipedia.


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