Work out how much of each dye and auxiliary to weigh, how much water and steam the batch uses and the cost per pound dyed; or convert yarn count between the systems used in spinning, knitting and synthetics.
Pre-sizing and estimating tool: results do not replace design, calculations or reports signed by a licensed professional, nor verification against the applicable codes and standards.
Cost of each product, water and steam per pound dyed, from largest to smallest.
Amount of each product per kilogram of goods and for the whole batch, with cost.
How many yards come in a pound for common Ne counts, compared with the yarn entered (highlighted bar).
Single yarn and plied resultant, without twist contraction.
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It has two modes. Dyeing turns the recipe (dyes in % owf and auxiliaries in g/L) into the amounts to weigh for the batch and works out water, steam and cost per pound dyed. Yarn count converts between Ne, Nm, tex, dtex and denier, handles plied yarns and gives the weight of a length and yards per pound.
Dyes are dosed in % on weight of fabric: 1.2% on 440 lb gives 5.3 lb. Auxiliaries such as salt and soda ash are dosed in g/L of bath, so they depend on the liquor ratio: 60 g/L in a 1:8 bath with 440 lb (about 422 gal) gives 211 lb of salt. That is why a shorter liquor saves auxiliaries but not dyes.
The 440 lb jersey batch at 1:8 uses a 422 gal bath and, with 6 rinses, about 2,950 gal of water (6.7 gal/lb). Heating the bath to 140 °F plus two washes at 194 °F takes about 1,506 lb of steam (3.4 lb/lb). The recipe costs $315, water $35 and steam $23: $373 per batch, or $0.85 per pound dyed.
The liquor ratio is in the machine manual or the standard recipe (jets 1:5 to 1:10, winch becks 1:15 to 1:30). Useful steam heat is the latent heat at the working pressure, about 900 Btu/lb at typical dyehouse pressures. Steam cost comes from the steam cost calculator, and water cost should include supply and effluent treatment.
Use tex = 590.5 ÷ Ne, Nm = 1,000 ÷ tex, dtex = 10 × tex and denier = 9 × tex. In the example, a Ne 30 yarn is 19.7 tex, Nm 50.8, 197 dtex and 177 denier; 1,000 yd weigh about 0.63 oz and one pound holds about 25,200 yd. In a 30/2 yarn, tex doubles (39.4) and Ne drops to 15.
Steam only covers heating water and goods at an average efficiency; open machines, long ramps and reused hot water change real use. Each rinse uses the bath volume, which may not hold for continuous or overflow rinsing. Twist contraction is not included in yarn count.
It depends mostly on shade: pale shades use under 1% dye and dark shades 4% or more. In the example, a medium shade with 2.5% reactive dyes costs about $0.85 per pound, 66% of it dyes. Water, steam and salt weigh more when the liquor ratio is long.
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