Spinning Production Calculation Formulas

Spinning is the process of manufacturing yarn from fiber during ring yarn manufacturing various machines are involved in the production namely Blow room, Carding, Comber, Draw frame, Speed Frame, and Ring frame. Calculations play a very crucial role during the yarn. In this article, we are discussing Spinning Production Calculation Formulas.

Some important spinning production calculations are mentioned in the following article which can be useful during the ring-spinning process, especially about spinning production formula, and draft calculation in spinning. Those formulas are very important in every step of the yarn manufacturing factory.

All the Spinning Production Calculation Formulas

Blow Room Production Calculations Formulae:

1. Cleaning efficiency % = Trash in mixing – Trash in lap * 100

Trash in mixing

2.Beater wise waste % = Beater wise waste collected in kgs

Total input for the particular beater in kgs * 100

3. Total blow room waste % = Total waste collected in kgs 100

Total input in

4. Beater wise trash % = Beater waste % Trash % in waste

100

5. Beats / inch = Beater rpm * No. of arms____________

Feed roller rpm *3.14 * feed roller dia (inch)

6. Weight of lap = lap length (Kg)

840 * Hank * 2.204

7. Production / scutcher/ 8 hrs = Weight /lap (kg)* 60 * 8 (kg)

Time (in minutes)

8. Draft of a scutcher = Surface speed of fluted lap roller

Surface speed of Regulating roller

9. % Waste = Loss in weight____

Weight of material fed

Carding Production Calculations Formulae:

1. Draft = Hank sliver delivered

Hank of lap fed

2. TPI = Rpm of can plate

Surface speed of calendar roller

3. Production / card / 8 hrs (kg)

= _Doffer dia (inch)* 3.14 * Doffer speed * 8 * 60 (Kg)

36 * Hank sliver delivered * 840 * 2.204

(OR)

= Surface speed of Doffer(inch/min) *60*8*Tension draft

36 * 840 * Hank of sliver * 2.204

4.Side shaft change bevel = Draft constant______

Calculated draft required

5. Nep count = Neps / 100 square inches of card web

6. Nep /2 grains = Standard Nep count

2.41

where,

Std. Nep count = Nep/100 sq. inch* Hk. sliver* width of card

0.12 * 40

7. Surface speed Ratio :

Cylinder to licker-in = 2.0 to 2.3(fine count)

Cylinder to Doffer = 25 to 30 (fine count)

Cleaning efficiency(%)=Trash in lap – Trash in sliver*100

Trash in lap

9. Draft constant = Draft * Draft wheel

10. Card Doffer speed = Cylinder dia in inches * 0.036 cyl.rpm

Doffer dia in inches *Staple length

11. Avg. capacity of card sliver can(Net wt in lb.) = F * D² * M

Where, F = 0.002557 (for card sliver)

= 0.002756 (for drawing sliver)

D = Dia in inches

H = Height in inches

12. Carding index(K) = nf

Where, n = Cylinder rpm

f = Surface speed of cylinder in meters

v = Licker-in speed in mpm

g = Weight of one Mt. of lap in gms.

13. Lickerin speed = Production in lb./hr * 116.66

2.75

14. Actual draft = Mechanical draft * 100

waste %

Comber Production Calculations Formula:

1. NIPS/MINFEED/NIPGRAINS/YARD160100-W%11NO OF HEADS

36 100 7000 2.204

2.PRODN/HR = 36.8TOTALDRAFTNIPS/MIN2(NO OF DELIVERYS)EFF

MAINDRAFT HANK OF SLIVER 2.204

PRODN/8 HR = FEED/NIP6081.0936NO OF HEADS100-NOILEFF

1000840100LAP HANK2.204

4.PRODN/8 HR = LAP WT IN GMS/MTR1-NOIL%NIPS/MIN480

¹⁰⁰

⁷FEED CHANGE GEAR

5.PRODN/8 HR = FEED/NIPNIP/MINGMS/MTR480NOOF HEADS(100-NOIL) EFF

10001000100

6.PRODN/8 HR = COILER CALENDER ROLLER SURFACE SPEED4802(100-NOILEFF

1000SLIVER HANK 100

0.00059

6. Comber fractionating index = Short fibre % in cbr sliver *100

Short fibre % in sliver lap

7. Production in kg

= Nips* feed/nip(mm)*Lap wt(gms/mt)*100-noil%*60*8*No.of Dblgs

Min 1000 1000 100

(OR)

= 0.0384 * LSF * (100- waste %)

1000

Where, L = Lap weight in gm/meter

F = Feed in mm / min

S = Speed in nips / min

W = noil extracted in %

8.Nips/min = Motor rpm * motor pulley__ * 0.2028

machine pulley

9.Feed/nip = * D

Where, D = Feed roller dia ( = 25mm )

S = Ratchet feed ( S= 16 )

10. % of noil = Mass of noil______________* 100

Mass of noil + Mass of Combed Sliver

11.Combing Efficiency

=(50% span length Cbd sliver – 50% Span length Cbd lap) * 100

50% span length of comber lap * % of waste extraction

Rating CE% ( for 13-18 % noil )

Good 1.0

poor 0.6

12.Nep removal efficiency

= Neps/100mg in cbr lap – Neps/100mg in Cbr sliver * 100

Neps / 100 mg in comber lap

Draw Frame Production Calculations Formulae:

1.Front roller speed = motor speedDia of motor pulley

Dia of front roller pulley

2.PRODUCTION IN LBS = DN608

36840COUNT

3.Production in kg = FR surface speed(mpm)* 1.0936 * 60* 8* Effy

840 * count * 2.204

4. Drawing can weight in kg = 1.5 * Height * (Diameter)²

1000

Where, Dia & Height in inches only

5.Draft constant = Draft * Draft wheel

6.Draft change wheel Reqd. = Present Draft wheel * Present Hank

Required Hank

7. Hank Delivered = Draft at drawing * Hank fed

No. of doublings

8.Hanks to Kgs = Hanks * 0.4536 per delivery

Count

______________________________

Speed Frame Production Calculations Formulae:

1. PRODUCTION PER SHIFT OF 8 HOURS IN KGS WITH 100% EFFICIENCY:

FRONT ROLLER DELIVERY(INCHES/MINUTE) x 60 x 8 x 120

= —————————————————

36 x 840 x HANK x 2.204

2. TWIST PER INCH = SPINDLE SPEED(RPM)

———————————

FRONT ROLLER DELILVERY(INCHES/MIN)

3. TWIST MULTIPLIER = TPI

——————

(HANK OR COUNT)1/2

4. PRODUCTION/SPINDLE/PER SHIFT OF 8 HOURS IN KGS AT 100% EFFICIENCY

= 1 x FRONT ROLLER DELIVERY(INCH/MIN)

———————————–

63 x COUNT

5. GRAMS/SPINDLE/SHIFT OF 8 HOURS

= SPINDLE SPEED x 7.2 x EFFICIENCY

——————————–

TPI x ROVING HANK

6. EXPECTED HANKS PER SHIFT OF 8 HOURS

= FRONT ROLLER DELIVERY(INCH/MIN) x 8 x 60 x EFFICIENCY

—————————————————–

36 x 840

7. EFFICIENCY = ACTUAL PRODUCTION

——————— x 100

PRODUCTION(CALCULATED)

8. FRONT ROLLER SPEED = 1440 x 160/230 x 102/63(Wz) x 28(g)/74(h)

x 27(K)/67 x 27 x 3.14/1000

= 17.049meters per minute.

Ring Frame Production Calculations Formulae:

1. Production / spl/ 8 hrs = π D N * 8 *60* Effy

TPI * Count * 100

2. Production / spl / hr in kg = Spl. Speed (Rpm) * 60 * Effy_

TPI * 36 * 840 * Count * 2.204

3. Required Ratchet wheel = Present wheel * Reqd. count

Present count

4. Traveller speed (rpm) = Spl speed( rpm)- Wdg on speed (rpm)

Where, Winding on speed = Roller Delivery (rpm)

Bobbin circumference

5. Spindle speed = Tin roller (rpm) * Dia of tin roller

Dia of spl Wharve

6. Traveller speed (ft/sec) = Spl speed * 3.14 * Ring dia(inch)

60*12

7. Twist contraction % = 2.64 TM – 4.82

That all on the Spinning Production Calculation Formulas.

Where, TM = Twist Multiplier

Written by: Mr.Yash Trivedi
VJTI, Mumbai-19
Email: [email protected]