Weaving Calculations

Yarn counts, fabric weight, warping, sizing, beams, reeds, cover factor, crimp, loom production, planning and feasibility of a weaving plant.

21 pages covering 28 lectures · 30 live worksheets. Every worksheet is live: blue figures are inputs, grey cells recalculate. Click a lecture below or use the list on the left.

Start with Lecture 00 →

Lectures

Lecture 00Course Outline – Weaving Calculations (TX-416)

What the course covers, how it is graded and where each lecture sits in the 15-week plan.

Lecture 01Counting Systems

Direct and indirect yarn numbering — Ne, Nm, tex, dtex and denier — and the single constant that links them.

Lecture 02Multiple Counts I – Yarns Together or Twisted

Resultant count and price of two or three yarns run together or plied, using the price of one hank.

Lecture 03Multiple Counts II – Yarns in Proportion

When the yarns are not present in equal numbers: weighting by the number of threads of each count.

Lecture 04Multiple Counts III – Proportions and Cost

Adding prices to the proportion method: the mean hank price and the price of the mixed yarn per 10 lb.

Lecture 05Weight of Fabric

From construction to ounces per square yard and grams per square metre — the calculation every merchandiser as…

Lecture 06Sett Calculations – Beams and Warping Production

How many warper’s beams an order needs, how many ends go on each, and how long the warper will take.

Lecture 07Beam Calculations

How much yarn fits on a beam — volume of the yarn annulus, packing density, weight, length and the fabric one …

Lecture 08Breakages and Sized Count

Expressing warp breaks per unit length so mills can be compared, and finding the count of yarn after sizing.

Lecture 09Cone Size

Matching cone weight to creel capacity: how many bags of yarn one creel can use, and how small a cone a short …

Lecture 10Warping Speed and Preparatory Capacity

From drum rpm to yards per shift, and two problems on how many warpers and sizers a loom shed needs.

Lecture 11Reed Calculations

Reed count, dents per inch, the Stockport sett, ends per dent for each weave and the maximum width a creel pai…

Lecture 12–13Cover Factor I & II

How much of the cloth area the yarns actually cover, the Ne cover factor used in mills, and the airjet weavabi…

Lecture 14Fabric Production

Loom output per day from rpm, picks and efficiency; then warp and weft bags for an order, loom-days and daily …

Lecture 15–16Crimp I & II – Peirce Geometry

Why yarns are longer than the cloth they make: the jammed plain weave with equal and unequal yarns, and the wa…

Lecture 17Blended Fabrics – Fibre Composition

Percentage of each fibre in a fabric whose warp and weft are different blends, and the elastane content of a c…

Lecture 18Sizing Cost Analysis

Relating sizing cost per kilogram to warp count across many articles, and forecasting the cost of a new count …

Lecture 19–21Planning I, II & III – Orders, Changeovers and Yarn

The booking-and-shipping schedule: daily production per quality, days required, finish and dispatch dates, loo…

Lecture 22Planning IV – Production Over Months

A day-by-day simulation: looms come on line one by one, stock builds up, and four shipments must be met on the…

Lecture 25Set Size Planning

For every quality on the loom plan: beams per set, ends per beam, cone length, sets of warping required and ba…

Lecture 27–28Feasibility I & II – Costing a Weaving Plant

Variable cost and contribution per metre for local and export sale, then the investment, running cost and retu…

Original lecture files

The classic course page with all the original lecture files is still available: Weaving Calculations — all lecture files ↗. The Google Drive folder of the course: open folder ↗.

00 · WC Course Outline (Doc) ↗01 · Lecture 01 Counting Systems (Sheet) ↗02 · Lecture 02 Multiple Counts I (Sheet) ↗03 · Lecture 03 Multiple Counts II (Sheet) ↗04 · Lecture 04 Multiple Counts III (Sheet) ↗05 · Lecture 05 Weight of Fabric (Sheet) ↗06 · Lecture 06 Sett Calculations (Sheet) ↗07 · Lecture 07 Beam Calculations (Sheet) ↗08 · Lecture 08 Breakage – Sized Count (Sheet) ↗09 · Lecture 09 Cone Size (Sheet) ↗10 · Lecture 10 Warping Speed (Sheet) ↗11 · Lecture 11 Reed Calculation (Sheet) ↗12–13 · Lecture 12 Cover Factor (Doc) ↗12–13 · Lecture 12 Cover Factor for Weaving (Sheet) ↗14 · Lecture 13 Fabric Production (Sheet) ↗15–16 · Lecture 14–15 Crimp (Doc) ↗17 · Lecture 17 Blended Fabrics (Sheet) ↗18 · Lecture 18 Sizing Cost Analysis (Sheet) ↗19–21 · Lecture 19–21 Planning (Excel) ↗22 · Lecture 22 Planning (Sheet) ↗25 · Lecture 25 Set Size Planning (Sheet) ↗27–28 · Lecture 27–28 Feasibility Study (Sheet) ↗