Warp Knitting

Warp Knitting: Runner Lengths to Fabric Weight & Machine Output

A warp knitter sets runners, not loop lengths. Two bars can reach the same GSM from very different places.

The Machine Bed, width and speed
E, needles/in

Needles per inch. A machine is one gauge

in

Knitting width of the bed, as the builder quotes it

courses/min

Running speed, not nameplate maximum

The Guide Bars What each bar feeds, and what it feeds
mm/rack

Yarn fed to one needle over one rack by the ground bar

dtex

Grams per 10,000 metres

mm/rack

Set to zero for a single-bar fabric

dtex

Grams per 10,000 metres

The Fabric Density, and what a rack means here
courses/cm

Measured on the state the answer is wanted for - greige or finished

courses

Courses a runner is quoted against. 480 is the usual convention

Fabric Weight

— g/m²

At the course density entered

Feed, Fabric & Output

Needles in the Bed
— nos
Yarn Fed per Rack
— m
Weight per Rack
— g
Share of Weight from Bar 1
— %
Bar 2 to Bar 1 Runner Ratio
— x
Fabric Made per Rack
— cm
Racks per Hour
— nos
Fabric Output
— m/h
Yarn Consumption
— kg/h

Runner is per needle, not per bar across the bed, and that is the single most common misreading of the figure: a bar does not feed 1250 mm, it feeds 1250 mm to each of the needles it laps. The bed count comes from gauge times working width, so a partial threading or a bar that laps only part of the width will overstate consumption here in proportion to the part not threaded. Bar share is reported because GSM cannot distinguish a short ground against a long inlay from two bars sharing the work, and those two fabrics behave differently under tension however alike they weigh. Course density is measured, not derived: it is the input the whole area calculation rests on, and taking it from a specification rather than from the cloth is how a weight calculation comes out confidently wrong. Yarn consumption per hour is yarn fed, which is not yarn bought - it excludes creel waste, the ends lost at a beam change and anything a stop mark costs. Elastane on a bar is quoted in dtex like anything else here, but it is fed under draft, and a runner measured on the machine already includes that draft while a figure taken from a recipe may not.

Warp Knitting: Runner Lengths to Fabric Weight & Machine Output — free, with the formula and a worked example, at Textile School.