Fleece Fabric Production Calculator | Knitting Calculation

Example

PRODUCTION CALCULATION (KNITTING)

FLEECE FABRIC

Here,
Machine Dia: 32”
Machine Gauge: 20
S.L: 4.50+3.00+1.60
Y/Count: 30/S CTN + 75D POLY + 20/S CVC (60/40) [Knit+Binder+Loop]
GSM: 260
RPM: 18
Efficiency: 85%
SHIFT= 11 HOURS

For Knit yarn P1:
Production= (Number of Needle X Feeder X RPM X Efficiency X S.L X 60 X SHIFT HOUR X 1.0923) / (840 X Count X 1000 X 2.2046)
= (3.1416X32X20X3X32X18X0.85X4.50X60X11X1.0923) / (840X30X1000X2.2046)
=172KG/SHIFT

For Binder yarn P2:
Production= (Number of Needle X Feeder X RPM X Efficiency X S.L X 60 X SHIFT HOUR X 1.0923) / (840 X Count X 1000 X 2.2046)
= (3.1416X32X20X3X32X18X0.85X3.00X60X11X1.0923) / (840X71X1000X2.2046)
= 48.57KG/SHIFT

For Loop Yarn P3:
Production= (Number of Needle X Feeder X RPM X Efficiency X S.L X 60 X SHIFT HOUR X 1.0923) / (840 X Count X 1000 X 2.2046)
= (3.1416X32X20X3X32X18X0.85X1.60X60X11X1.0923) / (840X20X1000X2.2046)
= 91.97 KG/SHIFT

AVARAGE PRODUCTION:
(172 + 48.57 + 91.97) / 3
= 104.18 KG/SHIFT

A fleece fabric production calculator supports accurate planning in circular knitting mills. The calculator estimates fabric weight, yarn consumption, machine output, and production cost. Textile engineers can use this tool to control quality, reduce waste, and meet delivery targets. Knit fleece fabric requires careful calculation because loop length, GSM, and brushing loss affect final yield.

Fleece fabric production depends on knitting parameters, yarn count, and machine settings. A calculator converts these variables into measurable production data. The tool supports decisions in fabric planning, capacity utilization, and cost estimation.

What Is Fleece Fabric in Knitting?

Basic Structure of Fleece Fabric

Fleece fabric uses a knitted base with an extra yarn system. The structure creates a soft inner pile after brushing. The outer surface remains smooth. Circular knitting machines produce fleece fabric in tubular form. The fabric later passes through dyeing and brushing processes.

The knit structure uses three-thread or two-thread fleece systems. The face yarn forms the outer surface. The tie-in yarn binds the structure. The fleece yarn forms loops on the back side. Brushing raises these loops to create warmth and softness.

Fleece Fabric Applications

Fleece fabric serves winter garments. The fabric supports hoodies, sweatshirts, joggers, and jackets. Sportswear brands prefer fleece for thermal comfort and low weight. Home textiles also use fleece for blankets and throws.

Why a Fleece Fabric Production Calculator Is Important

Control of Fabric GSM

Fabric GSM controls garment weight and performance. A calculator links loop length, yarn count, and stitch density to GSM. Engineers use GSM calculation to meet buyer specifications. Stable GSM reduces rejection during inspection.

Accurate Yarn Consumption Estimation

Yarn cost forms a major part of fleece fabric cost. A production calculator estimates yarn consumption per kilogram or per meter of fabric. The tool helps procurement teams plan yarn orders. Accurate estimation prevents excess stock and shortage.

Knitting Machine Output Planning

Knitting calculation defines daily and monthly production capacity. The calculator estimates fabric output based on RPM, machine diameter, gauge, and efficiency. Production teams use this data for delivery planning.

Inputs for Fleece Fabric Production Calculation

Machine Parameters

Machine diameter affects fabric width and productivity. Gauge controls stitch density. Number of feeders influences output speed. RPM defines fabric length per hour. These parameters form the base of knitting calculation.

Yarn Specifications

Yarn count defines fabric fineness. Common fleece yarn counts include 26 Ne, 30 Ne, and 34 Ne. Polyester, cotton, and blended yarns serve fleece production. Yarn twist and strength affect knitting efficiency.

Loop Length and Stitch Density

Loop length controls fabric weight and softness. Short loop length increases GSM. Long loop length reduces weight and improves drape. Stitch density balances strength and comfort.

Formula Overview

Fabric GSM Calculation

Fabric GSM depends on yarn count and loop length. Engineers calculate stitch length per course and wale. The calculator converts stitch length into fabric weight per square meter. Consistent GSM supports shade matching and brushing performance.

Yarn Consumption Calculation

Yarn consumption equals fabric weight plus process loss. Fleece fabric faces brushing loss and trimming loss. The calculator adds a standard loss percentage. Mills usually apply 6–10% loss for fleece fabric.

Knitting Output Calculation

Knitting output depends on RPM, feeders, and efficiency. The calculator estimates fabric length per hour. The tool then converts length into weight using GSM. Production managers use this value for shift planning.

Step-by-Step Use of a Fleece Fabric Production Calculator

Step 1: Enter Machine Data

The user inputs machine diameter, gauge, feeders, and RPM. These values define stitch formation speed. Accurate machine data improves output accuracy.

Step 2: Enter Yarn Details

The user selects yarn count and yarn type. The calculator adjusts weight based on yarn linear density. Separate entries exist for face yarn and fleece yarn.

Step 3: Set Loop Length and GSM Target

The user inputs loop length or target GSM. The calculator links both values. Engineers adjust loop length to meet GSM targets.

Step 4: Review Output and Yarn Requirement

The calculator shows fabric production per hour and yarn consumption per kilogram. The result supports cost calculation and planning.

Role of the Calculator in Cost Estimation

H3: Knitting Cost Control

Knitting cost includes machine depreciation, power, labor, and maintenance. The calculator estimates cost per kilogram by dividing total cost by output. Accurate output data improves costing accuracy.

Support for Price Quotation

Merchandisers use knitting calculation for buyer quotations. Reliable fabric cost builds buyer trust. Consistent calculation reduces price disputes.

Quality Control Benefits in Fleece Fabric Production

Reduction of GSM Variation

Consistent calculation reduces GSM fluctuation. Stable GSM improves dye uptake and brushing quality. Quality teams rely on calculated targets during production.

Control of Brushing Loss

Brushing raises fleece loops but removes fiber mass. Calculated loss allowance prevents underestimation of yarn consumption. The calculator supports realistic planning.

Integration with Modern Knitting Mills

Digital Production Planning

Modern mills use digital calculators and ERP systems. The fleece fabric production calculator integrates with planning software. Digital data improves traceability and reporting.

Support for Sustainable Manufacturing

Accurate calculation reduces waste and overproduction. Lower yarn waste supports sustainability goals. Efficient planning reduces energy consumption per kilogram of fabric.

Future Trends in Fleece Fabric Production Calculation

Automation and AI Support

Advanced calculators use machine data sensors. Real-time data improves calculation accuracy. Automation reduces manual error in knitting calculation.

Demand for Lightweight and Functional Fleece

Brands demand lightweight fleece with thermal performance. Accurate GSM and loop control support this trend. Calculators help engineers meet precise specifications.

A fleece fabric production calculator acts as a planning backbone for knitting mills. The tool links machine settings, yarn data, and fabric targets into clear production values. Textile engineers, merchandisers, and planners rely on this calculation for efficiency, quality, and cost control. Accurate knitting calculation supports competitive fleece fabric manufacturing in modern textile markets.