USEFUL FORMULAE IN SPINNING
A) YARN NUMBERING SYSTEM:
1. INDIRECT SYSTEM:
a) ENGLISH COUNT (Ne) Total [Link] Hanks
= -----------------
Weight in pounds
Length in Yards
= --------------------
840 * wt in lbs
Length in yards
= ------------------------------
840 * Wt in Kg * 2.202
Length in yards
= -------------------------------
840 * Wt in gms * 2.202
64.8
= ------------- ( For 120Yds Lea)
Wt in gm
Length in yards
b) ENGLISH WORSTED COUNT = --------------------
560*wt in lbs
97.3
= ----------- (For 120 Yds Lea)
wt in gms
Length in yards
c) ENGLISH WOOLEN COUNT = --------------------
256*wt in lbs
212.9
= ------------- ( For 120Yds Lea)
Wt in gms
d) ENGLISH LINEN COUNT Length in yards
= -----------------------
300*wt in lbs
181.65
= ----------------- ( For 120Yds Lea)
wt in gms
e) METRIC COUNT ( Nm) Length in mtrs
= -----------------------
1000*wt in kg
Length in mtrs
= -------------------
wt in gms
2. DIRECT NUMBERING SYSTEM :
a) TEX Wt in gms *1000
= ----------------------
Length in mtr
1
b) DENIER Wt in gms * 9000
= ----------------------
Length in mtr
Some conversions :
1. Ne 590.6
= --------
Tex
2. Ne 5315
= ---------
Denier
3. Ne = Nm * 1.69
4. Denier = Tex * 9
2. COTTON TESTING:
a) Uniformity Ratio 50% S.L.
= ----------- * 100
2.5%S.L
b) Floating Fibre Index = ((2.5%s.l/Mean Len)-1)*100))
Mean Length ( inch) = ( 50% S.l. in inches -0.075)*2
c) Fiber Quality Index
i) ICC Mode 2.5% S.L * U.R.* G/Tex*maturity
= ---------------------------------------
Micronaire
ii)HVI Mode Mean Len(mm)* G/Tex
= -------------------------------
Micronaire
iii) General 50%S.L * G/tex
= ----------------------
Micronaire
d) Denier = Micronaire * 0.354
e) Spinning Consistency Index
SCI = - 412.7+2.9*g/tex - 9.32*mic + 49.28*2.5%s.l+8.72*U.R
+0.65*Rd
2
BLOW ROOM
[Link] Rupture% (2.5% s.l of previous beating pt - 2.5% of present
beater)
= -------------------------------------------------------------- *100
2.5% s.l of previous beating point
(Neps/gm in present [Link] - Neps/gm in previous
beating point)
[Link] generation = --------------------------------------------------------------- *100
Neps/gm in previous beating point
(Trash(gm)in previous beating point - trash in
present beating point)
3. Cleaning Efficiency = ------------------------------------------------------------------- *100
Trash in previous beating point
4. Determining the amount of waste
Production during test time(Kg)= Card production rate from line kg/hr x test time hrs.
Amount of waste removed ( Kg)
* Waste% = --------------------------------------------- x 100
Production during test + waste(kg)
5. STOP/GO Ratio:
Running time of machine(operating hrs)
Stop/ Go Ratio = --------------------------------------------------------
Actual study time
CARD
S.S of Doffer x 60 x 8
[Link] ( Kg/Shift) = ----------------------------------- x Eff
840 x 36 x 2.202 x hank
Del Speed in Ypm x 60x8
= --------------------------------------- x Eff
840 x 2.202 x Hank
Del Speed in MPM x60x8x1.093
= ------------------------------------------------ x Eff
840 x 2.202 x Hank
Del Speed in MPM
= 0.283 x ------------------------------ x Eff
Slr Hank
[Link] Hank 30000 *Micronaire
= -----------------------------gm/mtr
25400
For C60 Card 45000 * Micronaire
= ------------------------ gm/mtr
25400
Sliver Hank (Ne) 0.59
= ---------
Gm/mtr.
3. Total Draft Hank of Sliver
= -------------------
3
Hank of lap
= 85 to 100
4. Doffer Speed
Doffer Circumference = 3.14 x D (in mtrs)
Doffer Speed [Link] in Mpm
= -------------------------------------------------------------
Doffer circumference [Link] bet. Doffer & take off roller
5. Nep Removal Efficiency
N.R.E. % Neps/gm in feed - neps/gm in sliver
= ------------------------------------------------- *100
Neps/gm in feed
6. Cleaning Efficiency%
Trash in feed - Trash in sliver
= ------------------------------------------- *100
Trash in Feed
7. Transfer Efficiency %
W x Doffer Surface speed
= --------- ---------------------------------- *100
36 x Cylinder rpm x q
W = Wt of one yard sliver
q = Cylinder load (gms)
BREAKER DRAWING
30000 x Micronaire
1. Delivery Sliver Hank = ----------------------------- gms/mtr
25400
0.59
Ne = ---------
gm/mtr
2. Roller Setting (Guide Line)
Front = 50%S.L.(mm) + 24 mm
Back = Front + 4 mm
[Link] F.R. x 60 x 8
3. Production (Kg/Shift) = ---------------------------------- x eff
840 x 36 x 2.202 x hank
[Link] YPM x 60 x 8
= -------------------------------- x eff
840 x 2.202 x hank
Del Speed in MPM x 60 x 8 x 1.093
= -------------------------------------------------- x eff
840 x 2.202 x hank
Del Speed in MPM
= 0.283 x ---------------------------- x eff
Sliver Hank
4
Hank Del.
4. Toatal Draft = ---------------- x No. of doublings
Hank fed
UNILAP
1. Lap Weight (Gm/Mtr) 460000 * Micronaire
= --------------------------
25400
[Link] of shell roller x 60 x 8
2. Production (Kg/Shift) = -----------------------------------------------x Eff
840x 36 x 2.202 x Hank
Del speed in ypm x 60 x 8
= ------------------------------------------- eff
840 x 2.202 x hank
Del speed in MPM x 60 x 8 x 1.093
= ------------------------------------------------- x eff
840 x 2.202 x hank
Del speed in MPM
= 0.283 x --------------------------- x eff
Lap hank
0.59
Hank = ----------------
Lap wt (gm/mtr)
Lap hank
3. Draft = --------------------- x No. of ends up
Fed sliver hank
COMBER
28000 * Mic.
1. Sliver Hank = ----------------- gm/mtr
25400
2. Production (Kg/Hr)
NPM x Feed /nip (mm) x lap wt (g/mt) x (100-noil %) x tension x no. of headsx60
= ------------- ------------------------------------------------------------------------------------------- x eff
1000x1000x100
Weight noil (gms)
3. Noil % = ---------------------------*100
Wt of noil+wt of sliver
4. Main Draft Gauge = 50% S.L.(mm) + 27mm
Hank Del
5. Total Draft = ----------
Hank Fed
6. Pre-Combing Draft = Total Draft at brk drg x total draft at unilap
= 8 to 10
7. Feed /nip Bottom roller dia (mm) x 3.14
= -------------------------------------
No. of teeth on ratchet wheel
5
8. Combing Efficiency 50%S.L. of comb sliver - 50% S.L of lap 100
=------------------------------------------------------- x ------
50%S.L of lap Noil%
9. SITRA COMBING INDEX (BY AFIS METHOD)
∆l x ∆ SFC x ∆ N
SCI = ------------------------
GFC x Noil%
Where,
∆l = Improvement in mean length(w) of sliver over lap in%.
∆ SFC = Removal of short fibre content from lap in %.
∆ N = NEP removal efficiency in%
GFC = Good fibre content in noil as %.
= Fibres having length longer than half of UQL (w) of sliver
Standard SCI 2100
= --------
Noil%
FINISHER DRAWFRAME
1. Sliver Hank 27000 xMicronaire
= ----------------------------- gm/mtr
25400
0.59
Ne = --------
Gm/mtr
[Link] F.R. x 60 x 8
2. Production (Kg/Shift) = ---------------------------------- x eff
840 x 36 x 2.202 x hank
[Link] YPM x 60 x 8
= -------------------------------- x eff
840 x 2.202 x hank
Del Speed in MPM x 60 x 8 x 1.093
= -------------------------------------------------- x eff
840 x 2.202 x hank
Del Speed in MPM
= 0.283 x ---------------------------- x eff
Sliver Hank
3. Bottom roller setting
Front Zone = 50% s.l(mm) + 24 mm
Back zone = Front zone + 3 or 4 mm
Hank Del
4. Total Draft = ---------- x no. of doubling
Hank Fed
5. Sliver test (A %):
6
Ktex (N-1) - Ktex (N)
N-1 = -------------------- x 100
Ktex (N)
Ktex (N+1) - Ktex (N)
N+1 = -------------------- x 100
Ktex (N)
Where N = Normal doubling.
6. Leveling Action Point (D30 / D35)
A = Front bottom setting
1132 = Distance between scanning roller to front roller.
Calculation -
i) X = A * 0.9
ii) Y = 1132 - X
iii) Z = Y * Table ten. Draft.
iv) W = Z/Main draft.
v) M = Back zone setting / Break draft.
vi) N = M / main draft.
Vii) L.A.P. = Z - M
SPEED FRAME
3250 x Micronaire
1. Roving Hank = ------------------------- gm/mtr
25400
0.59
Ne = -------
Gm/mtr
2. Roller Setting
Back zone setting = 50% S.L(mm)+40 mm
3. Production:
F.R.D (“/min) x60x8
Kg/spl/shift = ------------------------------------ x eff
840x36x2.202xRoving hank
Spl Speed x60x8
= ------------------------------------ x eff
840x36x2.202xhk xTPI
Spl speed
= 7.2x --------------------------- x eff.
Roving hank x TPI
7.2 Spl speed
= -----x ---------------------------- x eff.
1000 roving hank x TPI
7
T.P.I. = T.M * √hank
T.M = (25 - (50%s.l+micronaire))/6
100% hank prod./spl/shift
FRS"/min * 60 *8
= ----------------
36 * 840
Spindle speed
FRS"/min = --------------
T.P.I
Or
Front roll speed (rpm) * bottom roll dia (mm)*3.14
FRS"/min = --------------------------------------------------------------------
39.37
Front Roller Delivery = (Bobbin Speed – Spindle Speed) x π x D
D= Bobbin Diameter in inches
Roving hank
4. Total Draft = -------------------
Fed sliver hank
5.12
5. Layers / cm = ---------
√hank
Hank at that stage - Hank at full stage
6. Stretch % = --------------------------------------------------- x 100
Hank at that stage
7. Coils per inch:
For coarse roving = T.M x 10√hank
For fine roving = T.M x 13√hank
8. Time required to build one bobbin:
(Wt of bobbin in ounces x TPI x hank)
= ----------------------------------------------- minutes
Spindle speed x 16
RING FRAME
1. Roller setting = 50% S.L (mm) +47 mm
2. Production:
F.R.D (“/min) x60x8
Gms/spl/shift = -------------------------------------- x eff
840x36x2.202xCount
Spl Speed x60x8
= ------------------------------------ x eff
840x36x2.202xCount xTPI
8
Spl speed
= 7.2x ---------------x eff.
Count X TPI
3. T.M = (50-(50%S.L+micronaire))/8
8.233
4. Spacer size = (-----------------------------------) +2.03
Spacer factor x divider x √Ne
Micronaire
Spacer factor = ----------------------
Maturity x 50% S.L.
Divider = (roving hank x r/f B.D.)+ (0.96/√[Link].M)
Ring dia (mm) x 3.14 x S.S
5. Traveller Speed = ------------------------------------- mtrs/sec
1000 x 60
6. Lappet Height = (2 x d) +5 mm
d = Bobbin tip dia (mm)
1
7. Lappet starting position = --- x Lift
3
8. Chase length = Ring Dia + 10%.
9. Twist contraction in cotton:
= (2.64 x T.M)-4.82
Twist contraction in staple fibre yarn
0.967 x √T.M
= -------------
(Count) 1/3
11. Doff weight = (Ring dia I inches) 2 x (Lift) x 3.25 Kgs.
WINDING
1. Production:
Del Speed in Ypm x60x8
Kg/Drum/Shift = ---------------------------------- x eff.
840 x 2.202 x Count
Del Speed in MPM x 60x 8 x 1.093
= ------------------------------------------------ x eff
840 x 2.202 x count
Del speed in MPM
= 0.283 x ----------------------------------- x eff
Count
2. Yarn tension = 10% of single yarn strength in gms.
9
Wax consumed
3. Wax Pick up% = ----------------------- x100
Net yarn weight
Strength of splice
4. Splice strength = -------------------------------- x100
Strength of normal yarn.
Mass
5. Density Of cone = -------------- x 1000 x 1000
Volume
Mass = Net yarn weight in gms.
1
Volume = ------- x 3.14x h x(D 2 +D xd+d2)
12
Where, D = Diameter of cone at base
d = Diameter of cone at nose.
h = Traverse length
6. Density of Cheese
Mass
Density = -------------- x 1000 x 1000
Volume
Volume of Full cheese (V2) = 3.14 x r2 x h:
r= radius of cheese; h= traverse
Volume of full cheese (V1) = 3.14x r2 x h
Yarn Volume (V) = V2-V1
QUALITY
1. CSP :
a) CSP = (310-Ne) x √FQI.
Lx S x M
FQI = ----------
F
L = 2.5% S.L
S = Gm/tex
M = Maturity
F = Fineness
b) CSP = ((180) x √FQI) + (13 x count) x (1+noil%/100))
Lx S
FQI = --------
F
L = Mean Length
S = Gm/tex
F = Fineness
2. RKM:
10
1.7 x count x(4 x lea str. + 11.5)
a) RKM = ---------------------------------------
1000
13 x count
b) RKM = (1.1 x √FQI+4.0) - (----------------)
150
3. Imperfections / Km
Q = (15.129-A-B+C+D)
---------------
100
Where,
A = (1.682) x (Micronaire / Maturity)
B = (0.646 x 50% S.L in mm)
C = (53.61 x Trash% in fin. d/f slr.)
D = (7.582 x Neps/gm in fin d/f slr.)
Hence,
IPI/km = (Q x Count x Count x 0.25)x((1-(0.2√noil)))
4. Sensitive Imperfections:
f x sfc(w)
a) Thin(-40)+Thick(+35) = 370 * ---------- + 1.0x d+20 x c+4.5 x s.s-750
L
Where,
f= Micronaire
SFC (w) = short fibre content by wt in comb sliver.
L = 2.5% S.L.
d = draft employed at r/f.
c = count spun.
s.s= spindle speed (rpm)
b) Neps (+140)
NCS x C3/2
-------------------
=
11
NCS = neps/gm in RSB sliver having size 450micron & above.
C = Count spun.
5. Deviation Rate in Yarn Mass
D.R. % = 3.56 x f+2.79 x SFC (w) +0.43 x d+0.744 x s.s+0.218x Ne - 43.7
f = Micronaire
SFC (w) = short fibre content by wt in comb sliver.
d = draft employed at r/f.
Ne = count spun.
s.s= spindle speed (in 1000s)
6. Yarn Elongation:
FL x FS x FE
CPIYE = ------------------
MIC x SFC (W)
FL = 2.5%S.L
FS = GM/TEX
FE = FIBRE ELONGATION%
MIC= MICRONAIRE
SFC (W)=SHORT FIBRE CONTENT IN COMB SLR.
11
630 x CPIYE x TM2
Yarn Elon. % = -------------------------
Count x S.S
7. Yarn Hairiness:
MIC x SFC (W)
CPIYH = -------------------
FL
MIC= MICRONAIRE
SFC (W) =SHORT FIBRE CONTENT IN COMB SLR.
FL = 2.5%S.L
275 x √CPIYH x √S.S
S3 = ---------------------------
T.M x √COUNT
Cveff
8. Index of irregularity = ---------
Cvlim
Cvlim = 100/√n
n = no. of fibers in yarn cross section = Tg/ Tf
Tg = Yarn count in Tex
Tf = Fibre fineness in mtex.
1
9. Yarn Diameter (inches) = -------------
28√count
12
