Calculating Greige Fabric Yield from Loom Speed and Sett
Calculate linear greige yield by dividing net picks per hour by pick density, adjusting reed width and warp length for crimp contraction.
Beam End Waste
Material Loss
Material loss in weaving preparation occurs when the trailing sections of warp yarns on a sizing beam cannot be fed into the loom. Weavers classify this residual length as beam end waste, which accumulates at the end of each sizing beam cycle. These lost segments cannot be drawn through the heald eyes and reed.
Consequently, the mill must discard them or sell them as low value reclamation fibre. The volume of this residue depends directly on the number of warp ends and the distance between the loom beam and the stop motion sensors.
Loom Setting
Mechanical constraints during the knotting and drawing in phases dictate the minimum length of warp that remains unweavable. In flax weaving mills, yarn stiffness and low elasticity make beam end waste a particularly expensive loss compared to cotton processing. Sizing operators adjust tension and beam alignment to minimize the leftover yarn.
Standard margins are documented in the mill level operational manual to guide the warping team.
Inventory Tracking
Production records in Chinese linen mills require the daily measurement of yarn losses to maintain accurate mass balance accounts. The shift supervisor records the weight of beam end waste on the weaving floor log. This data enters the monthly yield ledger to calculate overall warp efficiency and material cost allocation.