Understanding Wastes in Knitting: How to Measure and Minimize It

In Knitting, Fabric waste significantly impacts profitability and sustainability. Today, we’ll dive deep into Loss 1—fabric waste loss—and explore how you can set up a system to measure and reduce it effectively.

Waste Loss Formula:

The simplest way to calculate waste loss is:

Input (yarn) – Output (fabric sold + claims) = Waste

But what exactly makes up this waste? Let’s break it down:

Defective Fabric: Fabric that doesn’t meet quality standards.

Yarn Wastage: Yarn lost during production.

Humidity Loss: Fabric weight changes due to humidity.

Fluff & Running Loss: Yarn lost as fluff or during machine runs.

Fabric Setting Time Loss: Time spent setting up machines for various fabric types.

Excess Yarn Purchased: Unused yarn due to inefficient planning.

Unsold Fabric: Fabric that remains unsold, reducing overall output.

Pro Tip: Sometimes people add water to fabric to increase weight for calculation purpose.

How to Set Up a System to Measure Waste Loss?

Here’s a step-by-step guide to establish an effective waste monitoring system:

  1. Track Every Yarn Batch
    Record each yarn batch that enters your factory. Compare this with the fabric sold from the same batch to identify discrepancies.
  2. Measure Fluff and Running Loss
    • Weigh the yarn before knitting.
    • Weigh the yarn after knitting.
    • Subtract the fabric weight produced from the initial yarn weight to calculate fluff and running loss.
  3. Recommendation: Measure at least 1,000 doffs to get a reliable average.
  4. Minimize Fabric Setting Loss
    Record key machine parameters like:
    • Loop Length
    • IRO Tension
    • Fabric Tension
  5. Fine-tuning these settings can reduce time wasted on fabric setting, enhancing production speed.
  6. Optimize Yarn Purchasing
    Over-purchasing yarn adds to waste over time. Regularly review your yarn usage data to improve planning and avoid excess stock.
  7. Track Defective Fabric Loss
    Break down defective fabric into:
    • Discarded or cut fabric.
    • Grade B and C fabrics that don’t meet premium standards.
  8. Measuring defective fabric precisely helps identify areas for improvement.

Simplify Waste Tracking with Technology

If manual tracking feels overwhelming, don’t worry—you’re not alone. Many manufacturers face challenges with pen-and-paper methods. To simplify the process, try our free software designed to measure waste precisely. Our system helps you input, track, and analyze your production data in real time, quickly identifying waste areas for improvement. [Click here to request free software.]

Take Action Today

By setting up a comprehensive waste monitoring system, you’ll not only reduce fabric losses but also improve your overall production efficiency and profitability. In our next post, we’ll dive deeper into fabric setting loss and share more tools to help optimize your operations.