Towel Yarn Consumption & Cost per Dozen

The formula

This is the expression the tool evaluates. Every term is named underneath, with the unit it must be supplied in.

How the result is derived

Step by step, from the values you type to the figure on screen.

1. The 9 inputs are read from the form on every keystroke: Finished Length, Finished Width, Finished Weight, Warp Shrinkage in Finishing, Weft Shrinkage in Finishing, Hem and Cut Allowance, Process Waste, Seconds and Rejects and Yarn Price.
2. Each value is checked against the accepted range in the input table below. A value outside its range stops the calculation rather than producing a misleading figure — the results blank out and a message appears.
3. The validated values are substituted into the expression above, which resolves Yarn per Dozen together with every supporting figure in one pass — no value is carried over from a previous entry.
4. The supporting outputs — Finished Weight per Towel, Loom-State Weight, Loom-State Area per Towel, Cloth Weight off the Loom, Yarn Bought per Towel, Yarn Bought per kg Sold, Yarn Cost per Towel, Yarn Cost per Dozen and Short per Dozen if Quoted on Finished Weight — come from the same pass, so they always describe the same case as the headline figure.
5. Results are rounded for display only. The full-precision value is used throughout the chain, so reading a rounded intermediate figure back into the tool by hand can shift the last digit.

What each input means

Where to read each value on the floor, the unit it must be in, and the range the tool accepts.

What the tool returns

The headline figure and every supporting value it is built from.

Worked example

The tool loads with this case already solved — the Yarn per Dozen shown above is its answer. Change one value and the difference from this baseline is the sensitivity of the result to that variable.

How to use it

1. Work through the input groups in order — The Towel as Sold, What the Loom Made and Yarn to Cloth. The defaults are a realistic case, so you can change one value at a time and watch what moves.
2. There is no calculate button. Every figure recalculates as you type or drag, which is what makes this usable for a what-if sweep rather than a single answer.
3. Read Yarn per Dozen in the dark results panel — that is the headline figure, expressed in kg.
4. Check the supporting rows underneath (Finished Weight per Towel, Loom-State Weight, Loom-State Area per Towel, Cloth Weight off the Loom, Yarn Bought per Towel, Yarn Bought per kg Sold, Yarn Cost per Towel, Yarn Cost per Dozen and Short per Dozen if Quoted on Finished Weight) before acting on the headline — they are where an implausible input usually shows itself first.
5. Reset to defaults returns every field to the reference case, which is the quickest way to check whether a surprising result came from the tool or from an input you had changed earlier.

Where this is used

• Process planning — establishing Yarn per Dozen before a trial is booked, so machine time and material in Commercial Costing & Advanced Textiles are committed against a calculated figure rather than an estimate.
• Costing and quotation — Yarn per Dozen is an input to the cost sheet, and quoting from a worked number rather than a remembered one is what keeps a margin intact.
• Troubleshooting — when the floor result drifts from plan, entering the measured values (starting with Finished Length) shows how much of the gap in Yarn per Dozen each variable explains.
• Teaching and study — the accepted ranges bracket normal Commercial Costing & Advanced Textiles practice, so moving one variable at a time shows the shape of the relationship rather than a single answer.

Assumptions and limits

• Loom-state weight is derived from the finished weight and the two shrinkages rather than entered, because a mill that already knows its loom-state weight does not need this sheet — it needs terry-pile-ratio, which builds that figure from the pile ratio, ends and picks. Seconds are charged their full yarn here: the towel was woven, finished and cut before anybody decided it was not a first.
• Every input is bounded to the range normal practice occupies (Finished Length 10 to 400 cm, Finished Width 10 to 300 cm and Finished Weight 100 to 1200 g/m², and so on for the rest). Those bounds are guard rails against typing errors, not a claim that the formula fails one unit outside them.
• The calculation is deterministic: the same inputs always give the same result. It carries no allowance for machine condition, operator skill, ambient conditions or lot-to-lot material variation unless an input above explicitly represents one.
• Nothing is sent anywhere. The maths runs in your browser, so the numbers you type never leave the page.

Questions people ask