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    Warping Calculations

    Uploaded by

    Nasir Sarwar
    The document provides information on calculating production rates, quality, and set lengths for warping machines. It discusses calculating production based on speed and run time. For quality, it describes two methods using weight or length to calculate pounds/break or breaks/10 million meters respectively. Higher quality yarn has lower break rates or higher pounds/break. Standards for different counts are also listed. Set calculations consider quality, ends, creels, cone weight/length, and number of beams to determine set length and number of bags. Beam length calculations use diameter, width, density and ends/beam to find mass and yarn length wound.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Warping Calculations

    Uploaded by

    Nasir Sarwar
    7K views5 pages
    The document provides information on calculating production rates, quality, and set lengths for warping machines. It discusses calculating production based on speed and run time. For quality, it describes two methods using weight or length to calculate pounds/break or breaks/10 million meters respectively. Higher quality yarn has lower break rates or higher pounds/break. Standards for different counts are also listed. Set calculations consider quality, ends, creels, cone weight/length, and number of beams to determine set length and number of bags. Beam length calculations use diameter, width, density and ends/beam to find mass and yarn length wound.

    Original Description:

    Textile yarn calculation for warping

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    The document provides information on calculating production rates, quality, and set lengths for warping machines. It discusses calculating production based on speed and run time. For quality, it describes two methods using weight or length to calculate pounds/break or breaks/10 million meters respectively. Higher quality yarn has lower break rates or higher pounds/break. Standards for different counts are also listed. Set calculations consider quality, ends, creels, cone weight/length, and number of beams to determine set length and number of bags. Beam length calculations use diameter, width, density and ends/beam to find mass and yarn length wound.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    7K views5 pages

    Warping Calculations

    Uploaded by

    Nasir Sarwar
    The document provides information on calculating production rates, quality, and set lengths for warping machines. It discusses calculating production based on speed and run time. For quality, it describes two methods using weight or length to calculate pounds/break or breaks/10 million meters respectively. Higher quality yarn has lower break rates or higher pounds/break. Standards for different counts are also listed. Set calculations consider quality, ends, creels, cone weight/length, and number of beams to determine set length and number of bags. Beam length calculations use diameter, width, density and ends/beam to find mass and yarn length wound.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    The key takeaways are about calculating warping production, quality measurements for yarn using breaks per million meters and pounds per break, factors considered for set calculations like quality, ends, creels, and cone information, and formulas used to calculate beam length and yarn length on beams.

    The quality of yarn is measured using two methods - the weight method which calculates pounds per break, and the length method which calculates breaks per 10 million meters. Higher pounds per break and lower breaks per 10 million meters indicate better quality yarn.

    When calculating set lengths, factors like quality, total ends, number of creels, cone weight, cone length, total number of bags, set length, and creel capacity must be considered.

    Warping Calculation Prepared by: M.

    Ahsan Mir

    PRODUCTION
    Production of a warping machine can be calculated as
    Production = Speed (rpm) * 60 * Time (hrs)

    Production capacity of a warping machine means production when it is run at maximum speed.
    So

    Production = 1200*60*24
    =1728000 m

    Quality of yarn: the quality of yarn is checked by two methods


    1. weight method
    2. length method
    1. Weight method
    Following is the formula to calculate the weight of warp
    Weight warp (lbs) = Length (yards) * Total Ends
    840* Count
    So to check the quality weight wise, there is a specific term used for it which is known as
    pounds/break (lbs/break)
    Lbs/break = Length (yards) * Ends
    840* Count*no. of breaks
    If value of lbs/break is high, than quality of yarn is good. If its low than more the b grade yarn
    will be.
    2. Length method
    In length method, no. of brakes in 10 million meters is calculated
    Break/
    10 million meters
    Break/10 million meters = 107*no of breaks
    Length (m)* Ends
    If breaks /10 million meters is low, than higher will be the quality of yarn and if its value is high
    than yarn will be of low quality.
    Warping Calculation Prepared by: M.Ahsan Mir

    16s Cotton 21s Cotton


    Brand Brake/10 Lbs/break Brand Brake/ Lbs/brake
    Mm 10mm
    Sun Raiz 9.30 84 Marral 6.69 93
    Dawood 7.08 115 Crescent Jute 7.71 80
    Mehmod 9.02 90 Best 5.25 116
    Mas.
    Asim 10.32 79 Altex 4.51 135
    Reliance 7.69 106 Colony 8.45 73
    Asim 10.20 80 Mehran 8.04 77
    Riaz 6.87 118 Marral 5.02 103
    2
    40 Cotton
    Brand Brake/10 Lbs/brak
    Mm
    Umer 10.01 65
    Din 12.10 54
    Umer 6.47 101
    Superior 16.28 40
    Umer 8.12 80
    Fazal cloth 13.70 48
    Kunjah 24.34 27

    Standards for these counts in Sapphire Diamond weaving unit is as follow


    16/1 = brakes/10MM less than 8, Lbs/ Brake more than 116
    21/1 = brakes/10MM less than 5.5, Lbs/ Brake more than 118
    40/2 = brakes/10MM less than 6, Lbs/ Brake more than 108
    Warping Calculation Prepared by: M.Ahsan Mir

    SET CALCULATIONS
    While performing set calculations while factors have to be considered
    -Quality - Total ends
    - No. of creels - Cone weight
    - Cone length - Total no. of bags
    - Set length - Creel Capacity

    Creel capacity 1170


    Machine Benniger
    Count 60
    Cone weight 4.167 lbs

    Quality 60 X 60 X 110
    180 X 106

    Total ends = ends / inch x width = 19800

    No of beams = Total ends


    Creel capacity
    = 19800
    1170
    = 16.92 = 17

    Ends/ beams = Total ends / No. of beams = 19800


    17
    = 1164.7059 = 1165 x 12= 13980, 1164 x 5= 5820
    = 13980 + 5820 = 19800
    Warping Calculation Prepared by: M.Ahsan Mir

    Cone length = Cone weight (lbs.) X 768.1 X count


    = 4.167 X 768.1 X 60
    = 192040 m

    We will take 2% cone remainder length taken = 190119 m

    We take set length by dividing length taken to the total no of beams

    Set length = cone length/ beam


    = 190119 m/17 = 11183.47 = 11183 mtrs
    Either we have no. of creels or total no. of bags
    We have 3 creels

    No of bags = Total ends X no of creels


    No of beams X cones/ bag

    = 19800 X 3
    17 X 24
    = 145.588bags = .588 x 24 = 14.112
    = 145 bags and 14 cones.

    BEAM LENGTH CALCULATIONS


    Ends/ beam = 1165
    Count = 60
    Density = 0.5 gm/cm*3
    Dia of flange = D = 1000mm = 100 cm
    Dia of barrel = d = 307mm = 30.7 cm
    Width of beam = W = 2400mm = 240 cm
    Volume = 3.147 [D*2 - d*2] X W
    4
    Warping Calculation Prepared by: M.Ahsan Mir

    = 3.147 [ (100)*2 - (30.7)*2 ] X 240


    4
    = 1707300 cm*3
    Mass = Volume X Density
    = 1707300 X 0.5
    = 853650.2 gm
    = 1881.94 lbs

    Weight (lbs) = Total length X Total ends/beam


    768.1 X count
    Total length = 1881.94 X 768.1 X 60
    953
    = 91104.0824 m
    = 91104 m

    Formula used in mill to calculate length of yarn on beam


    Dia of flange = D = 1000 mm
    Dia of Barrel = d = 21 mm
    Length of yarn on beam = ((D*2-d*2) x 1.585 x Count of yarn)
    Reed count x reed filling

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