USEFUL FORMULAE IN SPINNING

A) YARN NUMBERING SYSTEM:

1. INDIRECT SYSTEM:
a) ENGLISH COUNT (Ne) Total No.Of 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

1.Fibre 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 beat.pt - Neps/gm in previous

beating point)
2.Nep 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
1.Production ( 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

2.Sliver 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 Del.Speed in Mpm

= -------------------------------------------------------------
Doffer circumference xTen.draft 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

S.S.Of F.R. x 60 x 8
3. Production (Kg/Shift) = ---------------------------------- x eff
840 x 36 x 2.202 x hank

Del.in 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

S.S.Speed 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

S.S.Of F.R. x 60 x 8
2. Production (Kg/Shift) = ---------------------------------- x eff
840 x 36 x 2.202 x hank

Del.in 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/√S.FT.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