Tuesday, October 18, 2011

How do calculate the yarn consumption of a Yarn dyed t-shirt?

Learn Apparel Merchandising, Learn Fashion design.
Today we will learn how we can book the yarn for bulk dyeing.

Suppose, you receive a yarn dyed t-shirt order from buyer. Details as below

Style: 100% cotton, Single jersey, 160 gsm yarn dyed round neck t-shirt.
Color:  Beige/Navy (only one combo)
Quantity: 10,000 pcs (in four sizes, S, M, L & XL)
Stripe: Beige 7 cm & Navy 1.5 cm (Total 8.5 cm)


Body length: 73 cm
Sleeve length: 19.5 cm
½ Chest: 52 cm


Consumption: 2.78 kgs/dozen (considering total wastage 18%) you may use this for pricing. Normally the wastage of yarn dyed garments depends on styling. 

Normal wastage for yarn dyed:
Dyeing (yarn) wastage: 6%
Knitting wastage: 3%
Wash wastage: 5%
So, you should need 116 kgs yarn to produce 100 kgs fabric

But be careful, during the bulk yarn booking you should booked the yarn based on the consumption you got by using pattern & marka. Some time I saw buyer asked for match the body stripe with sleeve then the cutting wastage become more than 5%.

We know the body length is 73 cm
Where, beige color stripe is 7 cm
And Navy color stripe is 1.5 cm
Then total length of one repetition is 8.5 cm
So, we need total (73/8.5) = 8.58824 repletion to complete a body (but here we will count 9 repetition for cutting & sewing wastage.)

So, total sum of Navy stripe will be (1.5 cm X 8.58824) = 12.8824 cm
And total sum of Beige color stripe will be (7 cm X 8.58824) = 60.1177 cm
So, 12.8824 cm + 60.1177 cm = 73 cm (total body length)

Now we just calculate the percentage of each color in a body

Navy color percentage in the body will be

= (12.8824 ÷ 73) %
= 17.65 %

= (60.1177÷73) %
= 82.35 %

= 17.65 + 82.35

= 100 %

So, now if the consumption is 2.78 kg

Then

Navy color will be = 0.49067 kg ( 2.78 kg X 17.65% )
And Beige color will be = 2.28933 kg ( 2.78 kg X 82.35% )

In this above way you can booked the yarn

Hope everything is clear to all.

Thanks & best regards
Bipul

18 comments:

  1. thank a lotttttttttttttt.

    would u pls write on:how to do fabric consumption on armhole depth and front and back neck drop with bindind width 1.5 cm for a tank top.for your reference i am sending u a measurement chart in your mail.pls write on that matter.

    rashed

    ReplyDelete
  2. OK, send me the measurement chart. I will try to answer you.

    Thanks
    Bipul

    ReplyDelete
  3. Can u explain what is meant by 2/3/4/5 line factory in apparels/woven factory. How many machines are actually required to add a line.

    ReplyDelete
    Replies
    1. The machine qty of lines depends on styling of specific items. Before setup a line you should know that how many process the style has.

      Thanks!

      Delete
  4. Can u plz tell me What is meant by 2/3/4 etc. line factory?

    ReplyDelete
  5. Actually for sewing a complete t-shirt, shirts & all others garments we need to do so many process and various type of machine.As Example: for a basic knitted t-shirt we need approximately 20 to 22 machines and we need different type of machine for different process. Such as we need Over lock machine for side seam and need flat lock machine for Body & sleeve hem. Now, as we have used 20/22 machine for a complete t-shirt so, we can call it as a line.

    Hope u are clear now.

    regards
    Bipul

    ReplyDelete
  6. Dear Brother,

    I liked the way of yarn dyed consumption. Thanks a lot.

    Javed.

    ReplyDelete
  7. Dear Brother,

    Above way for yarn dyed consumption is really nice. Thanks.

    Javed.

    ReplyDelete
  8. Dear Mr.Bipul,

    I would like to thank you for helping to learn Merchandising basic & very needful way.

    Thanks in advance
    Shohag
    Sr.Merchandising
    Gazipur

    ReplyDelete
  9. Many thanks as you publish your consumption theory of y/d knitted fabric consumption

    Thanks and Br
    Mostaquim
    Sr Merchandiser
    Narayangonj
    01712768923

    ReplyDelete
  10. Dear sir,

    Pls clear to me why ur consumption will be 2.78kg/doz

    According to ur formula my consumption is 2.65kg./doz & I explain below:

    Fabrication : S/J 160 gsm 100%CTN
    BL : 73cm
    Slv : 19.5cm
    Chest : 52 cm

    Now (BL+slv+allowance) X (Chest+allowance) X 2 (part) X 160 (gsm) / 10000000 + 18%
    So, (73+19.5+10) X (52+5) X 2 X 160 / 10000000 + 18%
    My result is 2.65kg/doz

    Pls check & Reply me.

    B/R

    Arafat

    ReplyDelete
  11. Dear Bipul vai thanks for your post. Now please see my easy way for Y/D booking

    Fabrication : S/J 160 gsm 100%CTN
    BL : 73cm
    Slv : 19.5cm
    Chest : 52 cm

    If consuption + 2.78

    Then we have to calculate like bellow for color yarn

    total consum/total repeat measurement*stripe measurement.

    2.78/8.5*1.5 = 0.49059 for color Navy (1.5 is stripe measurement)
    2.78/8.5*7 = 2.28942 for color Beige (7 is stripe measurement)

    Now Navy + Beige = 0.49059+2.28942=2.7800

    ReplyDelete
  12. Dear Bipul vai thanks for your post. Now please see my easy way for Y/D booking

    Fabrication : S/J 160 gsm 100%CTN
    BL : 73cm
    Slv : 19.5cm
    Chest : 52 cm

    If consuption + 2.78

    Then we have to calculate like bellow for color yarn

    total consum/total repeat measurement*stripe measurement.

    2.78/8.5*1.5 = 0.49059 for color Navy (1.5 is stripe measurement)
    2.78/8.5*7 = 2.28942 for color Beige (7 is stripe measurement)

    Now Navy + Beige = 0.49059+2.28942=2.7800

    ReplyDelete
  13. Dear Bipul vai thanks for your post. Now please see my easy way for Y/D booking

    Fabrication : S/J 160 gsm 100%CTN
    BL : 73cm
    Slv : 19.5cm
    Chest : 52 cm

    If consuption + 2.78

    Then we have to calculate like bellow for color yarn

    total consum/total repeat measurement*stripe measurement.

    2.78/8.5*1.5 = 0.49059 for color Navy (1.5 is stripe measurement)
    2.78/8.5*7 = 2.28942 for color Beige (7 is stripe measurement)

    Now Navy + Beige = 0.49059+2.28942=2.7800

    ReplyDelete
  14. Dear Bipul vai Thanks for your post. I have a easy way to calculate Yarn dyeing Booking.

    Please see as bellow
    Fabrication : S/J 160 gsm 100%CTN
    BL : 73cm
    Slv : 19.5cm
    Chest : 52 cm
    If consumption 2.78 kgs

    Then we have to calculate like this
    Total consumption/Repeat measurement* Stripe measurement.

    Here Total consumption 2.78
    Repeat measurement 1.5+7=8.5
    Stripe measurement for Navy color=1.5 and Beige color = 7

    So, as per rule 2.78/8.5*1.5= .4906 for Navy color
    2.78/8.5*7 =2.2894 For Beige Color.

    Total consumption + Nave + Beige = 2.78

    Hope every one can understand this.

    ReplyDelete
  15. how can we find yarn consumption for kintted (s/j , Ly s/j, Laucost, fleece , Terry fleece messs, interlock ?


    plz plz answer me

    ReplyDelete





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