Woven fabric weaving loss and dyeing loss calculation method

Here is a rewritten and improved version of the original content in English, with added details to make it more natural and comprehensive: --- **Note: The following data is based on actual production experience and is for reference only.** **Yarn Losses:** - **Dyed Yarn:** - Chemical fiber: 4% - T/C (Terry/Cotton): 5% - CVC (Cotton Viscose Blend): 6% - Combed Cotton: 7% - **Weaving Losses:** - Long Fiber Chemical Fiber: 0.3% - Short Fiber Chemical Fiber: 1.5% - T/C Blending Material: 2% - CVC & Combed Cotton Material: 2.5% - Color Yarn: 3–6% The loss can be higher depending on several factors. For example, if the raw material quality is poor, especially from less reliable suppliers, the loss tends to increase. Thicker yarns often result in lower cotton staple fiber quality, which also increases the loss. In some cases, even with the same specification of materials, the loss can vary significantly. For instance, a well-known supplier in Shanghai used to have a loss of only 1.5%, while a company in Jiangsu had a 4% loss during weaving. The differences in dyeing and finishing processes can also lead to large variations in final results. Smaller orders tend to have higher losses. For example, when producing 15 kg of fabric, you may need about 1 kg of adjustment fabric, but for 1,500 kg, you might only need 1 kg as well. This shows that the scale of the order has a direct impact on the overall loss. For yarn-dyed fabrics, the more colors involved, the higher the loss. Similarly, when different types of fibers are interwoven, the greater the number of different materials, the higher the loss. **Dyeing and Finishing Losses:** - **Sewing Shaping:** 3–4% - **Long Fiber Chemical Fiber:** 4.5–5% - **Short Fiber Chemical Fiber:** 4.5–5.5% - **T/C:** 4.5–5.5% - **CVC (Dark Colors):** 6–6.5% - **CVC (Medium Colors):** 6.5–7% - **CVC (Bleaching & Light Colors):** 7–8% - **Cotton (Dark Colors):** 7–7.5% - **Cotton (Medium Colors):** 7.5–8% - **Cotton (Light Colors):** 8–9% - **Bleaching:** 8–9% - **Enzyme Treatment:** 2.5% - **Trimming:** (Cut Width / Original Width × 100) × 0.2% - **Resin Treatment:** If no length change, the loss is small. If weight increases, the loss is minimal. - **Brushing:** 1–2.5% - **Sanding:** 1–2.5% - **After Brushing & Sanding (Shaving):** 1–3% - **CVC Velvet (Steamed, Woven, Grey Fabric Shear Loss):** 11.5–13% - **CVC Velvet Dyeing to Finished Product:** 11.5–13% - **Flower Ash or Yarn-Dyed CVC Velvet Water Finish:** 6–10% - **Ordinary Fleece Dyeing:** 11–14% - **Superfine Fleece Dyeing:** 15–19% - **Flower Ash Fleece Dyeing:** 10–12% - **Double Brush Double Fleece Dyeing:** 4–6% It’s important to match the weaving style with the type of shaker used; otherwise, the loss can be significant. **Formula for Fabric Dyeing and Finishing Loss:** > Fabric Dyeing and Finishing Loss = [(Raw Fabric Weight – Finished Fabric Weight) / Raw Fabric Weight] × 100% **Main Factors Contributing to Fabric Dyeing and Finishing Loss:** 1. Removal of oils, waxes, pectins, and other impurities during bleaching and dyeing. 2. Breakage and shedding of free fibers during the process, including raising and shearing in finishing. 3. Corrosion or dissolution of fabric after treatments like acid reduction, alkali reduction, enzyme treatment, or chemical washing. 4. Shear loss during fabric processing, such as cutting to the seam head or making cylinder samples. 5. Quality issues in the fabric that cannot be repaired, leading to repeated losses. 6. Resurgence of grey fabric compared to finished products. 7. Dyes and additives being absorbed into the fabric. **Personal Summary:** 1. **Knitted Cotton Fabric Loss:** - Bleaching: 7–10% - Light Color: 7–9% - Medium Dark: 6–9% 2. **Polyester-Cotton Knitted Fabric Loss:** - Bleaching: 7–9% - Light Color: 6–8% - Medium-Dark: 5–8% 3. **Polyester-Knitted Fabric Loss:** - 4–6% (If loss is high, it may indicate excessive oil in the raw material) 4. **Loose Fabric Damage > Compact Fabric** 5. **Roving Fabric Damage > Spun Yarn Fabric** This information is based on years of practical experience in textile manufacturing and can help in estimating production costs and managing expectations in the dyeing and finishing process.

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