Consumption of Sweater

Buyer provides you a sample by mentioning the below information-

Yarn: 100% Acrylic, 2/36S, 2ply
Sample Weight: 180gm
Knitting: 12 G/G, (22) Rib
Specifications: Plain knit placket, Slit, 2 pockets.
Now prepare the yarn consumption of the above sweater item.
Solution:
Buyer provided sample weight- 180gm
Merchandiser made sample weight-190gm
Let, buyer approved the sample weight and style according to measurement chart.

Now,
Yarn needed per dozen garments = (190 12) = 2280gm= 5.03lb (1lb= 453.6gm)
In case of acrylic yarn, wastage% is 5-7%.
So, after adding wastage% total quantity of yarn needed per dozen garments is-,
= 5.03 + 6% (here, we accept 6% wastage)
= 5.33lbs per dozen
So, Yarn needed per dozen garments is 5.33lbs.

Consumption of yarn or consumption of sweater / dz =wt/dz+wastage10%

If the stripe sample then pull the Yarn from sweater keep the yarn color
separately make wt of each color.

What is Gauge in the Sweater World?

Gauge, commonly abbreviated as "GG", is one of the most important terms in the
sweater knitting world. Gauge is a unit, measuring the number of needles in one inch
width of the machine needle bed. Typical range of gauge on flatbed knitting machines
is from 3GG to 14GG. At 3GG, there are three needle hooks per inch on the needle bed,
thus creating a more coarse look sweater. And at 14GG, there are 14 needle hooks per
inch on the needle bed, creating a finer looking sweater. Gauge is one of the main
components that defines the thickness and look of a sweater.

Typically, the thicker the sweater gets the lower the gauge number. Therefore, 3GG
machines is more often used in the winter time to knit chunkier sweaters and 12GG is
used year round to knit cover up cardigans that can be worn in all seasons. Anything
higher than 16GG creates a style that would feel more like a knit product (such as Tee's)
rather than sweaters to the consumers.

To determine what gauge of machine to use, below chart is handy. Although keep in
mind, multiple plies of yarns can be twisted together to knit so that finer count yarns
can be used on lower gauge machines as well.

Typical Gauge Range and Recommended Yarn Count

*Note: 1 Nm = 1000 meters of yarns in 1 kilogram

Sweater GAUGE calculation system:

1.5 gauge contains : from 9 to 13 plies(thick)
3 gauge contains : from 6 to 8 plies ( Low)
5 gauge contains : from 3 to 5 plies( Low)

7 gauge contains : from 2 to 3 plies( Low)

10 gauge contains : from 1 to 2 plies( Low)

12 gauge contains : only 1 plies( Low)

Example-2: Sweaters color is white, order quantity 5000 pcs, yarn consumption in
dozen 11.5 lbs. how many lbs. of yarn you need for this order?

Answer: 11.5 / 12 x 5000 + 10% = 5324 lbs. Formula: yarn consumption dozen / 12 x
5000 + 10% (wastage)

DESING & STICH:

1) JERSEY- CABLE,
2) REVERSE
3) RIB
4) PONTAL
PROCEDURE OF SWEATER PRODUCTION:

WINDING YARN

KNITTING

LINKING ( ATTACH ALL PART BY LINKING M/C)

TRIMMING (In this process, loose yarns are trimmed by using trimmer)

MENDING( If found any knitting defects in the sweater, then its repaired here with the
help of needle)

WASH

LABELING

IRONING( STEAM IRON)

INSPECTION BY QUALITY TEAM

FOLDING AND PACKING

FINAL INSPECTION

SHIPMENT
Accessories

Regular : here-

Mainlable-

Size label -

Carelabel-

Hangtag-

Price tag-

Polybag-

Blister bag- 2pc( average idea 1 poly bag consist 6pc garments)

Carton-

Sewing thread -0.07 cone / dz( average idea){ 1 cone =4000mtr)

Carton sticker

Tag pin

Tissue

Silicajel

Scotch tape-0.07 roll/dz( average idea){ 1roll= 40yd}

Gum tape-0.07roll/dz( average idea){ 1 roll= 40yd}

Poly sticker

Blister sticker

Carton sticker

Auxiliary :

1.Zipper :

Nylon , Plastic/Vislon, Metal zipper

Nylon- (t-shirt), plastic/ vislon ( sweater), Metal( woven)

2.Button
Productivity for basic design:

3GG=13-14PC /PER DAY PER MC

5GG=10-11/PER DAY PER MC

7GG=7-8PC/PER DAY PER MC

12GG=5-6 PC / PER DAY PER MC

Wash done in garments- ( Most commonly)

Acid wash
Enzyme wash

Quantity break down :

LET,
NAME OF YARN:100% COTTON
WT PER DZ:16LBS/DZ
TOTAL ORDER QUANTITY:1000DZ
GG=5GG

Black : 1 2 2 1 = total -6
Red 1 2 2 1 = total -6
White 2 2 2 2 = total -8
Blue 1 1 1 1 = total -4
5pc 7pc 7pc 5pc = 24

Total quantity in pc
Step- 1) Total Assortment=
Quantity of each assortment
 (100012)pc

=
24pc

=500 Assortment

Step-2) color wise quantity =total assortment quantity of each color in each
assortment

Black=500assortment6pcs=3000pc=3000/12=250dz
Red=500assortment6pcs=3000pc=3000/12=250dz
White=500assortment8pcs=4000pc=4000/12=333.33dz
Blue=500assortment4pcs=2000pc=2000/12=167 dz

Step-3)size wise quantity= total assortment quantity of each size in each

assortment

Black=500assortment 5pcs=
Red=500assortment 7pcs=
White=500assortment7pcs=
Blue=500assortment 5pcs=

Step -4)Quantity of each size and each color=

BLACK= S=30001/6=.PC
M=30002/6= PC
L=30002/6=.. PC
XL=30001/6= ..PC

CM RANGE FOR BASIC STYLE / DESIGN STICH:

3 GG=$21-$23/DZ
5G=24-$25/DZ
7GG=$26-$27/Dz
12GG=$28-$30/DZ
#CALCULATION OF CM FOR CRITICAL OR SEMI CRITICAL: ( BY PM)

1) WINDING: ( PER LBS 3TK)

= 16LBS+10%wastage
=17.63tk
=53tk/dz

2) KNITTING:SEMISKILEED OPERATOR (360TK /DAY)

-PRODUCTIVITY=6PC
- PER PC COST =360/6PC
=60TAKA PER PC
PRODUCTION BONUS 20% OF PER PC COST
=6020%=72TAKA PER PC
PER DZ COST=7212=864TAKA

3) LINKING(13TK-15TK)/PC
- PER DZ COST=1312=156TAKA

4)TRIMMING TO MENDING( 10TK PER PC)

PER DZ COST=1012=120TK

5)FIXED OR FINISHED COST INCLUED PROFIT( $12-$16) PER DZ

TOTAL=53+864+156+120=1193TAKA/DZ=1193/76=$15.69/DZ

NOW ADD FIXED COST=$15.69+$12-=$28/DZ

Note:

For local yarn wastage=10%

For foreign yarn wastsge=12%

COSTING SEMI OR CRITICAL :

1) Costing of yarn= consumption yarn price+ wastage%

=16.00lbs$2.00/lbs+10%
=$35.20/dz
2) Costing of accessories( $3.00-$3.50/dz)
3) Cost of CM=$28/DZ

TOTAL=1+2+3=$35.20+$3.50+$28=$66.70/DZ

4 )Commercial cost : (2% above subtotal)

=$66.702%=$1.33/dz

TOTAL FOB:$ 66.70+$1.33=$68.03/DZ

=68.03/12=$5.67/PC

Some other fact : - if C&F/ CIF then freight charge ( $2.50/dz- $3.00/dz)

-If have zipper-

( Plastic & vislon zipper)

Short zipper- $1.50/dz

Long zipper-2.20-2.30/dz

( Nylon zipper)

Short zipper- $0.80-$0.90/dz

Long zipper-$1.20-$1.30/dz
 Zipper attachment cost-

Short zipper- $1.00/dz

Long zipper- $1.50/dz

Cost of zipper = zipper price + attachment cost

If have button:
Plastic or horn : $1.00-$1.50/DZ
Cost of Embroidery :
a) 12000 stich = 1unit
b) Per unit cost= $0 .20-0.30/unit
c) Cost of embro= $2.00-$5.00/dz
d) Buyer =( $2.50-$3.50)/dz
e) Hand embro cost=$2.00-$7.00/dz

If have crochet :

1PART=25-30TK PER PC
=$4.50-$5.00/dz

If have print :

quality= rubber/plastic soul

A) Per color cost= $0.50-$0.60/dz

=$2.00-$4.00/dz

b) Reactive print= $24-$28/dz

sweater wash:

( $7.00-$8.00)/DZ

mainly done- ACID WASH

ENZYME WASH