This document discusses standard production estimation in spinning mills. It begins by outlining the typical sequence of machinery used in carded and combed yarn production. It then explains yarn numbering systems including direct, indirect and count conversion factors. Formulas are provided for estimating production of various processes like blowroom, carding, draw frame, fly frame, ring frame, comber and cone winding. Key process objectives and variables that impact production calculations like efficiency, speed and count are defined.

1. ESTIMATION OF
STANDARD PRODUCTION IN SPINNING MILLS
G.Santhana Krishnan
Liaison and consultation division
SITRA

2. SEQUENCE OF MACHINERY
CARDED COUNTS
Blow room
Cards
Fly frame
Ring frame
COMBED COUNTS
Blow room
Cards
Pre comber
draw frame
Fly frame
Ring frame
Blow room
Cards
Draw frame
Fly frame
Ring frame
Unilap /Lap former
Comber
Post comber
draw frame
Sliver lap
Ribbon lap
Comber
Breaker
draw frame
Finisher
draw frame

3. YARN NUMBERING SYSTEM
Yarn numbering system
In direct system
Direct system
Denier
(D)
Tex
(T)
English
count
(Ne)
Metric
count
(Nm)
French
count
(Nf)

4. YARN NUMBERING – DIRECT SYSTEM
In this system, unit length is taken as fixed and its
weight is measured
Tex (T) - Weight in grams/ Length in 1000 m
Denier (D) - Weight in grams/ Length in 9000 m
Example:-
40 Tex :- A length of 1000 meter gives 40 grams of
weight
120 Denier :- A length of 9000 meter gives 120 grams
of weight
In this system, yarn becomes coarser / heavier as the
count number increases

5. YARN NUMBERING – INDIRECT SYSTEM
In this system, unit weight is taken as fixed and its
length is measured
English (Ne) - Length in hanks of 840 yards
Weight in 1 pound
Metric (Nm) - Length in km / weight in 1000 g
French (Nf) - Length in km / weight in 500 g
Example:-
Ne 5 :- In one pound of yarn weight there are 4200
(840 x 5) yards of yarn length.
In this system, the yarn becomes finer as the count number
increases.

6. YARN NUMBERING SYSTEM
DIRECT SYSTEM
Tex (T) - Weight in grams/ Length in 1000 m
Denier (D) - Weight in grams/ Length in 9000 m
INDIRECT SYSTEM
English (Ne) - Length in hanks of 840 yards
Weight in 1 pound
Metric (Nm) - Length in km/ weight in 1000 g
French (Nf) - Length in km/ weight in 500 g

7. COUNT CONVERSION FACTORS
Ne - Nm / 1.69
Ne - 590.5 / T
Ne - 5315 / D
T - D / 9
Nm - 2 x Nf
Ne – English count; Nm – Metric count
Nf – French count; T – Tex; D – Deniar

8. COUNT CONVERSION CALCULATIONS
Calculate the following
1. Convert Tex 40 to English count (Ne) ?
2. Convert Nf 40 to English count (Ne)?
Answer :- Ne = 590.5 / 40 = 14.8
Answer :- Nm = 2 x Nf = 2 x 40 = 80
Ne = Nm / 1.69
= 47.33

9. COUNT CONVERSION CALCULATIONS
Calculate the following
3. Convert Ne 50 in to Tex, Denier, and metric
count?
Answer:-
Tex = 590.5 / Ne = 590.5 / 50 = 11.8
Denier = 5315 / Ne = 5315 / 50 = 106.3
Nm = 1.69 x Ne = 1.69 x 50 = 84.5

10. CONVERSION UNITS - BASICS
1 metre = 1.094 yards
1 yard = 0.914 m
1 yard = 36 inches
1 lea = 120 yards
1 hank = 840 yards
1 kg = 2.205 pounds
1 pound = 453.6 g

11. CONVERSION UNITS - BASICS
Length in
metres
= 1.693 x Count (Ne) x
Weight in
grams
Length in
metres
=
0.59
Weight in
grams Count (Ne)
x
Count of yarn
from lea (Ne) =
64.8
Lea weight in grams

12. WRAP REEL

13. BASIC CALCULATIONS
Calculate the following
1. Calculate the length of yarn in the package of
2500 gm of Ne: 40s?
Answer:-
Length in meter = 1.693 x 40 x 2500
= 169300 mtr

14. BASIC CALCULATIONS
Calculate the following
2. Calculate the weight of yarn in the Ne: 20s
package containing length of yarn about
84745 mtr ?
Answer:-
Weight in grams = (0.59/20) x 84745
= 2500 gm

15. BASIC DEFINITIONS
Length in hanks of 840 yards
Weight in pounds
Count (Ne) =
0.59
Weight in grams/metre
ie. =
Surface
speed
=  x
Front
roller
dia.(in
ches)
x
Speed of the roller
in rpm

16. BASIC DEFINITIONS
Hank of delivery material
Hank of feed material
Draft =
Actual production x 100
Calculated production
Efficiency
(%)
=

17. BLOWROOM

18. BLOWROOM

19. BLOWROOM
The main objective of blow room is
1. Opening
2. Cleaning
3. Dust removal
4. Blending / mixing
5. Even material fed to subsequent process (Card)

20. BLOWROOM LAP

21. BLOW ROOM PRODUCTION CALCULATION
Production per
scutcher per 8
hours (kg)
Delivery
speed
(mpm) x 60 x 8 x 1.094 Eff (%)
100
x
Lap hank
(Ne)
x 840 x 2.205
=
Delivery speed
(mpm)
0.2835 x Eff (%)
100
x
Lap hank (Ne)
=
ie.

22. BLOW ROOM PRODUCTION CALCULATION
Delivery speed = 8.5 mpm
Lap hank = 0.0014
Machine efficiency = 85%
Calculate the blow room production per
scutcher per 8 hours ?
Production per
scutcher per 8
hours (kg)
0.2835 x 8.5
0.0014
85
100
x
=
= 1463.0 kg per 8 hours

23. CARDING

24. CARDING
The main objective of carding process is
1. Open the flocks into individual fibers
2. Cleaning and elimination of impurities
3. Removal of neps
4. Formation of sliver

25. CARDING PRODUCTION CALCULATION
Production per
machine per 8
hours (kg)
Delivery
speed
(mpm) x 60 x 8 x 1.094 Eff (%)
100
x
sliver
hank (Ne)
x 840 x 2.205
=
Delivery speed
(mpm)
0.2835 x Eff (%)
100
x
Sliver hank (Ne)
=
ie.

26. CARD PRODUCTION FROM DOFFER SPEED
Production per
card per 8
hours (kg)
doffer
dia (”)
=
60 x 8
2.205
 x x
doffer
speed
(rpm)
Sliver hank (Ne) x 36 x 840
Tension
draft
x
Eff (%)
100
x
x
ie. =
Doffer speed (rpm)
Sliver hank (Ne)
x
0.61 x Tension
draft
Eff (%)
100
x
For 27” doffer dia:

27. DRAW FRAME

28. DRAWFRAME
The main objective of draw frame process is
1. Doubling of slivers
2. Parallelization of fibers
3. Blending
4. Small dust removal
5. Removal of hooked fibres

29. DRAW FRAME PRODUCTION CALCULATION
Production per
delivery per 8
hours (kg)
Delivery
speed
(mpm) x 60 x 8 x 1.094 Eff (%)
100
x
sliver
hank (Ne)
x 840 x 2.205
=
Delivery speed
(mpm)
0.2835 x Eff (%)
100
x
Sliver hank (Ne)
=
ie.

30. DRAW FRAME – HANK METER PRODUCTION
Production
per delivery
per 8 hours
(hanks)
=
Surface
speed of
front roller
(mpm)
0.6251 x
Surface
speed of front
roller (mpm)
Eff (%)
100
x
60 x 8 x 1.094
840
Eff (%)
100
x
x
ie. =

31. DRAW FRAME PRODUCTION CALCULATION
Answer : 781 kg per delivery per 8 hours
Delivery speed (mpm) = 450
Sliver hank (Ne) = 0.120
Efficiency = 73.5%
Calculate the prodn. per delivery per 8 hours in kg ?

32. FLYFRAME

33. FLYFRAME

34. FLY FRAME / SIMPLEX
The main objective of fly frame process is
1. Attenuation of drawn sliver to form roving of
required count by drafting
2. Insert a small amount of twist to give required
strength of roving
3. Wind the twisted roving on to the bobbin
4. Build the roving bobbin such a form which will
facilitate handling, withdrawing and transfer to the
next process

35. FLY FRAMES
Production /spindle /8 hours (kg)
=
ie. =
Spindle speed (rpm)
TPI x Roving hank (Ne)
x
x
Eff (%)
100
x
60 x 8
36 x 840 x 2.205
x
Spindle speed (rpm)
TPI x Roving hank (Ne)
Eff (%)
100
7.2
1000
where, TPI = TM x V roving hank

36. FLYFRAME PRODUCTION CALCULATION
Answer : 5.04 kg per spindle per 8 hours
Spindle speed (rpm) = 950
Twist per inch (TPI) = 1.39
Roving hank (Ne) = 0.80
Machine efficiency % = 82
Number of spindles per machine =120
Calculate the production
per spindle per 8 hours in kg ?

37. FLYFRAME PRODUCTION CALCULATION
Answer :
748.0 kg per machine per 8 hours
6.23 kg per spindle per 8 hours
Spindle speed (rpm) = 850
Twist per inch (TPI) = 1.15
Roving hank (Ne) = 0.70
Machine efficiency % = 82
Number of spindles per machine =120
Calculate the production per machine
per 8 hours in kg ?

38. RING FRAME

39. RING FRAME

40. RING FRAME
The main objective of ring frame is
1. To draft the roving fed to the ring spinning frame i.e.,
to convert roving into very fine strand called yarn.
2. To impart strength to yarn by inserting the necessary
amount of twist
3. To wind the twisted strand of yarn on a bobbin or
tube (handy and transportable package)

41. RING FRAMES
Production /spindle /8 hours (g)
=
ie. =
Spindle speed (rpm)
TPI x Yarn count (Ne)
x
x
Eff (%)
100
x
60 x 8 x 1000
36 x 840 x 2.205
x
Spindle speed (rpm)
TPI x Yarn count (Ne)
Eff (%)
100
where, TPI = TM x V yarn count
7.2

42. RINGFRAME PRODUCTION CALCULATION
Answer : 110 grams per spindle per 8 hours
Spindle speed (rpm) = 18000
Yarn count (Ne) = 40.0
Twist per inch (TPI) = 27.5
Machine efficiency % = 93.5
Number of spindles per machine =1200
Calculate the production
per spindle per 8 hours in grams ?

43. RINGFRAME PRODUCTION CALCULATION
Answer :
159 g per spindle per 8 hours
191 kg per machine per 8 hours
Spindle speed (rpm) = 17000
Yarn count (Ne) = 30.0
Twist per inch (TPI) = 23.8
Machine efficiency % = 93.0
Number of spindles per machine =1200
Calculate the production
per machine per 8 hours in kg ?

44. FLY FRAMES/ RING FRAMES
Production /spindle /8 hours (hanks)
= x
x
Spindle speed (rpm)
TPI
Eff (%)
100
PRODUCTION IN HANKS
1
63
HANK TO KG CONVERSION (expected)
Production
per doff
(kg)
x
0.455 x
No of hanks
Yarn count (or)
roving hank
=
No. of
spindles
per
frame

45. LAPFORMER / UNILAP

46. SLIVER LAP, RIBBON LAP & LAP FORMER
Production
per machine
per 8 hours
(kg)
=
Surface
speed of
lap roll
(mpm)
60 x 8 x
Eff (%)
100
x
x
(or)
Lap
weight
(g/m)
1000
Delivery speed
(mpm)
0.2835 x Eff (%)
100
x
Lap hank (Ne)
=
ie.

47. UNILAP PRODUCTION CALCULATION
Answer : 2808 kg per delivery per 8 hours
Delivery speed (mpm) = 120
Lap weight in grams per meter = 65
Efficiency = 75%
Calculate the production per machine per 8 hours in
kg ?

48. COMBER

49. COMBER
The main objective of comber process is
1. To remove short fibers (Noil)
2. To remove remaining impurities in the lap
3. To remove of neps
4. To produce sliver with more uniformity

50. COMBERS
Production
/comber /8
hours (kg)
=
480
TD
S x x
L
1000
x
F
1000
x
(100 – w)
100
Eff (%)
100
x X No.of heads (8)
0.0035 x S x L x F x
Eff (%)
100
x
ie. =
(100 – w)
100
S – Speed in nips/min; L – Lap weight in g/m
F – Feed nip in mpm; w – Noil extracted
TD – Lap tension draft (1.10)

51. COMBER PRODUCTION CALCULATION
Answer : 340 kg per comber per 8 hours
Comber speed (nips per minute) = 400
Feed per nip (mm) = 4.7
Lap weight (grams per meter) = 70
Machine efficiency % = 90
Noil % = 18%
Calculate the production
per comber per 8 hours in kg ?

52. CONE WINDING
The main objective of cone winding process are
1. To eliminate yarn faults such as long thick places,
long thin places, short thick places, short thin places,
etc.,
2. To wind continuous length of yarns on cones for
downstream process (weaving / knitting)
3. Size and shape of the package should be proper, so
that it can be unwound easily.

53. CONE WINDING
Cone winding
Automatic cone
winding
Manual cone
winding

54. MANUAL CONE WINDING

55. AUTOMATIC CONE WINDING

56. AUTOMATIC CONE WINDING

57. CONE WINDING
Production
per drum
per 8 hours
(kg)
Drum speed
(mpm) x 60 x 8 x 1.094 Eff (%)
100
x
Count (Ne) x 840 x 2.205
=
Delivery speed of
drum (mpm)
0.2835 x Eff (%)
100
x
Yarn count (Ne)
=
ie.

58. CONE WINDING CALCULATION
Answer : 5.52 kg per drum per 8 hours
Delivery speed drum (mpm) = 1300
Yarn count (Ne) = 50.0
Efficiency = 75%
Number of drums per machine = 60
Calculate the production per drum
per 8 hours in kg ?

59. CONE WINDING CALCULATION
Answer :
516 Kg per machine per 8 hours
5.52 kg per drum per 8 hours
Delivery speed drum (mpm) = 1300
Yarn count (Ne) = 30.0
Efficiency = 70%
Number of drums per machine = 60
Calculate the production per machine
per 8 hours in kg ?

60. TWO-FOR-ONE TWISTER (TFO)

61. TWO-FOR-ONE TWISTER (TFO)

62. TWO-FOR-ONE TWISTER
Production /spindle /8 hours (g)
=
ie. =
2 x Spindle speed (rpm)
TPI x Actual count (Ne)
x
x
Eff (%)
100
x
60 x 8 x 1000
36 x 840 x 2.205
x
Spindle speed (rpm)
TPI x Actual count (Ne)
Eff (%)
100
where, TPI = TM x V yarn count
14.4

63. TWO-FOR ONE TWISTER CALCULATION
Answer :
570 g per spindle per 8 hours
Spindle speed (rpm) = 10000
Yarn count (Ne) = 2/30
Efficiency = 95%
Twist per inch (TPI) = 16.0
Calculate the production per spindle
per 8 hours in g ?

64. RING DOUBLING

65. RING DOUBLING
Production /spindle /8 hours (g)
=
ie. =
Spindle speed (rpm)
TPI x Actual count (Ne)
x
x
Eff (%)
100
x
60 x 8 x 1000
36 x 840 x 2.205
x
Spindle speed (rpm)
TPI x Actual count (Ne)
Eff (%)
100
where, TPI = TM x V yarn count
7.2

66. RING DOUBLING CALCULATION
Answer :
179 g per spindle per 8 hours
Spindle speed (rpm) = 10000
Yarn count (Ne) = 2/40
Efficiency = 96%
Twist per inch (TPI) = 19.3
Calculate the production per spindle
per 8 hours in g ?

67. RING DOUBLING CALCULATION
Answer :
44 g per spindle per 8 hours
Spindle speed (rpm) = 11500
Yarn count (Ne) = 2/120
Efficiency = 97.5%
Twist per inch (TPI) = 30.7
Calculate the production per spindle
per 8 hours in g ?

68. RING DOUBLING CALCULATION
Answer :
44 g per spindle per 8 hours
Spindle speed (rpm) = 11500
Yarn count (Ne) = 2/120
Efficiency = 97.5%
Twist per inch (TPI) = 30.7
Calculate the production per machine
per 8 hours in g ?

69. REELING
Production per reel per 840 yard (kg)
For SHPR =
18.144 x No. of doffs
Yarn count (Ne)
Note: In case of 1000 metre hank, multiply the figures
from the above formula by 1.3
For DHPR
(or) DHCR
18.144 x No. of doffs x 2
Yarn count (Ne)
(for 840 yard hank)
=

70. PRODUCTION PLANNING IN
SPINNING MILL

71. SPIN PLAN
Calculate a spin plan for a 12000 spindle mill
manufacturing Ne: 40s carded yarn.

72. SPIN PLAN – RING FRAME PRODUCTION
Data required:
Actual count (Ne) :
Average spindle speed (rpm) :
Twist per inch :
Machine efficiency (%) :
Total number of spindles :
Number of spindles per ring frame :
To calculate:
Total number of ring frames :
Production per spindle per 8 hours (g) :
Production per day @ 100% SU (kg) :

73. REQUIREMENT OF FLYFRAME
Data required:
Production required in fly frame (kg) :
Actual hank (Ne) :
Average spindle speed (rpm) :
Twist per inch :
Machine efficiency (%) :
To calculate:
Production per spindle per 8 hours (kg) :
Production per spindle per day (kg) :
Number of spindles required :
Number of machines required :
Number of machines to be allotted :

74. REQUIREMENT OF FINISHER DRAWFRAME
Data required:
Production required in draw frame (kg) :
Actual hank (Ne) :
Delivery speed (mpm) :
Machine efficiency (%) :
To calculate:
Production per delivery per 8 hours (kg) :
Production per machine per day (kg) :
Number of machines required :
Number of machines to be allotted :

75. REQUIREMENT OF BREAKER DRAWFRAME
Data required:
Production required in draw frame (kg) :
Actual hank (Ne) :
Delivery speed (mpm) :
Machine efficiency (%) :
To calculate:
Production per delivery per 8 hours (kg) :
Production per delivery per day (kg) :
Number of delivery required :
Number of machines required :
Number of machines to be alloted :

76. CARDING REQUIREMENT
Data required:
Production required in cards (kg) :
Actual hank (Ne) :
Delivery speed (mpm) :
Machine efficiency (%) :
To calculate:
Production per card per 8 hours (kg) :
Production per card per day (kg) :
Number of cards required :
Number of cards to be alloted :

77. MIXING REQUIREMENT
To calculate
Production required from blowroom (kg) :
Rawmaterial required for mixing per day (kg) :

78. DRUMS REQUIRED IN CONE WINDING PROCESS
Data required:
Drum speed (mpm) :
Actual hank (Ne) :
Machine efficiency (%) :
To calculate:
Production per drum per 8 hours (kg) :
Production per drum per day (kg) :
Number of drums required :
Number of machines required :

79. SPIN PLAN
Calculate a spin plan for a 30000 spindle mill
manufacturing Ne: 50s carded yarn.

80. Process parameters for calculating spin plan
Process parameters Value
Actual count (Ne) 50.0
Average spindle speed (rpm) 18000
Twist per inch 30.41
Machine efficiency % 94.0
Total number of spindles 30000
Number of spindles per ring frame 1200
Waste received in ring frame % 2.0
Department : Ring frame

81. Process parameters for calculating spin plan
Process parameters Value
Actual hank (Ne) 1.55
Average spindle speed (rpm) 1100
Twist per inch 1.56
Machine efficiency % 86.5
Waste received in fly frame % 0.5
Number of spindles per frame 132
Department : Fly frame

82. Process parameters for calculating spin plan
Process parameters Value
Actual hank (Ne) 0.140
Delivery speed (mpm) 450
Machine efficiency % 80.0
Waste received in finisher draw frame % 0.3
Number of delivery per machine 1
Department : Finisher draw frame

83. Process parameters for calculating spin plan
Process parameters Value
Actual hank (Ne) 0.140
Delivery speed (mpm) 400
Machine efficiency % 77.5
Waste received in breaker draw frame % 0.3
Number of delivery per machine 2
Department : Breaker draw frame

84. Process parameters for calculating spin plan
Process parameters Value
Actual hank (Ne) 0.140
Delivery speed (mpm) 130
Machine efficiency % 95
Waste received in card % 4.5
Department : Carding

85. Process parameters for calculating spin plan
Process parameters Value
Waste received in blow room% 2.0
Department : Mixing

86. Process parameters for calculating spin plan
Process parameters Value
Actual count (Ne) 50.0
Drum speed (mpm) 1300
Machine efficiency % 75.0
Number of drums per machine 60
Department : Cone winding

87. SPIN PLAN
Calculate a spin plan for a 12000 spindle mill
manufacturing Ne: 40s combed yarn.

88. Model spinplan