Production Calculation of Blow Room

Calculation of Blow Room:

The section where the supplied compressed bale is turned into a uniform lap of a
particular length by opening, cleaning, blending, or mixing is called blow room. It
is the starting of the spinning operation where the fiber is opened, cleaned,
mixed, micro dust removed, and evened thus passed to carding machine without
increasing fiber rupture, fiber neps, broken seed particles, and without removing
more good fibers. In this article, I have given the example with the calculation
of Blow Room.

Fig:
Blow room section
Production Calculation of Blow Room

* 1 lb = 16 ounce = 7000 grain = 453.6 gm.

* 1 Metric ton = 2204 lb.
* 1 kg = 2.2046 lb.

Problem-1:
A lap contains 2% trash after processed in B/R having a cleaning efficiency of
80%. Find the trash % in raw cotton.
Solution:

We know,

………………………………Trash remains after processing

Cleaning efficiency = …………………………………………….
…………………………………………….Total trash

…………………..2%
=> 80 = ………………….
…………….Total Trash

=> Total Trash = 2/100 x 80

=> Total Trash = 2.5%. (Ans.)

Problem-2:
Bottom calender roller dia = 7 inches, rpm = 10 & wt. of every yds lap is 12 oz and
cleaning efficiency 75%. Find out the production of B/R per hour.

Solution:

…………………………………..3.14 x 7 x 10 x 60 x 75 x 12
Production/hr of B/R = ……………………………………….
……………………………………………….36 16 x 100

= 206.06 lb (Ans.)

Problem-3:
If lap length constant is 720, then set the change pinion for 40 yds lap.

Solution:

………………………….lap length constant

Change pinion = ………………………………..
………………………………….lap length

……720
= ………..
…….40
= 18 T (Ans)

Problem-4:
If lap wt. is 15 oz per yds, find the hank.

Solution:

………………1 yds x16 ounce

Hank = ……………………..………..
…………….840 yds x15 ounce

= 0.0012 hank. (ANS)

Problem-5:
If lap wt. – (a) 15 lb/yds, (b) 15 lb/m, (c) 15 grain/ yds, (d) 15gt/m, (e) 15gm/yd,
(f) 15gm/m. Find the hank.

Solution:

…………………1 yds x16 lb

a. Hank = …………………….. = 0.0000793 hank. (Ans)
……………….840 yds x15 lb

………………….1 m x1 lb
b. Hank = ……………..……….
……………….840 yds x15 lb

……..1.1 yds x1 lb
= ………………………
…..840 yds x15 lb

= 0.0000873 (Ans)

……………….1 yds x 7000 grain

c. Hank = ……………………………… = 0.55 (Ans)
………………..840 yds x15 grain

………………..1 m x 7000 gr
d. Hank = …………………………
………………..840 yds x15 gr
….1.1 x 7000
= ……………….
……840 x15

= 0.611 (Ans).

………………1 yds x 453.6 gm

e. Hank = ……………..………… = 0.036. (Ans)
……………….840 yds x15 gm

……………..1 m x 453.6 gm
f. Hank = ………………………
……………..840 yds x15 gm

…..1.1 x 453.6
= …………………
…….840 x 15

= 0.0396. (Ans)

Problem-6:
Find the no. of lapper hour in scutcher m/c of Bottom calender roller dia = 7
inch, rpm = 12, efficiency 80%. Lap length 40 yds.

Solution:
………………………………π x 7 x12 x 80 x 60
Production of m/c = ………………………….. yds
…………………………………….36 x 100

= 351.85 yds.

……………………351.85
No. of lap = ………………
………………………40

= 8.79
= 9 (ANS)

Problem-7:
Find the no. of lap per hour in scutcher m/c of Bottom calender roller dia = 7
inch, rpm = 12, efficiency 80%, lap wt. 14 oz/yds.
Solution:

………………………3.14 x 7 x12 x 0.80 x 60 x 8 x 14

Production = ……………………………………..…………… lbs
…………………………………………36 x16

= 2461.76 lbs

…..2461.76
= ……………. metric ton
……..2204

= 1.117 metric ton. (Ans)

Problem-8:
If in a xsutcher m/c, rpm of B.C.R. is 10, dia 7 inches, lap wt. 12 oz/yd. Find the
production/hr at 90% efficiency.

Solution:

……………………..3.14 x 7 x 10 x 12 x 60 x 90
Production = ………………………………………….. lbs
……………………………….36 x 16 x 100

= 247.275 lbs (ANS)

Problem-9:
Calculation of Blow Room line with 2 scutchers if B.C.R. dia = 7 inch, rpm = 10,
Efficiency 90%, wastes 4%, lap wt. 14oz/yd.

Solution:

………………………3.14 x 7 x10 x1x 60 x 90 x (100 – 4) x 2 x14

Production = ……………………………………………..……………………. lbs
…………………………………….36 x 16 x 100 x 100

= 553.896 lbs. (Ans)

Problem-10:
Calculate production/he of a B/R line if, r.p.m. of B.C.R. = 14, Dis = 18 cm,, lap
hank = 0.0012, efficiency 80%, no. of scutcher = 2.

Solution:

………………………3.14 x18 x14 x 60 x 0.80 x 2

Production = ………………………………….………….. lbs
………………………..36 x 2.546 x 840 x 0.0012

= 822.2 lbs. (Ans)

Problem-11:
Find the B/R cleaning efficiency, if the waste in Raw cotton = 6%, waste in sliver
= 0.4%. Carding, cleaning efficiency 75%.

Solution:

…………………………………………..waste in lap – waste in sliver

Carding cleaning efficiency = ………………………..………………… X 100
………………………………………………………..waste in lap

……………x – 0.4
=> 75 = …………. x 100
………………..x

=> x = 1.6%.

………………………………………6 – 1.6
B/R cleaning efficiency = …………….. x 100
……………………………………………6
= 73% (Ans.)

Problem-12:
The trash control of feed cotton is 3%. After passing the beater 2% waste is
extracted, of which 15% is good fibre, what is the cleaning efficiency of the
beater?

Solution:
……………………………..100-15
2% waste extraction, ……..…… x 2 = 1.7% of the original trash has been taken out
by beater.
………………………………..100

(3-1.7) = 1.3% trash remains in the mtls, which are delivered from the beater.

…………………………………Original T.C – T.C. in delivered cotton

Cleaning Efficiency = ……………………………………………………………. x 100
………………………………………………………Original T.C

…..3-1.3
= ……….. x 100
………3

= 56.66% (Ans.)

Problem-13:
Find out beats/inch from the following data- Beater r.p.m. = 720, no. of striker =
16, Feed roller r.p.m. = 24, Dia of feed roller = 3 inch.

Solution:

Beats / min = Beater r.p.m. x no. of striker

= 720 x 16 no.s
= 11520 no.s

Surface speed of feed roller = π DN

= 3.14 x 3 x 24
= 226.08

……………………….11520
Beats / inch = ……………….
………………………226.80

= 50.96 (Ans.)

Problem-14:
The trash content of cotton as fed to Beater 3.6%. The waste extraction is 1.5% of
which 80% is trash. What is the cleaning efficiency of the beater?
Solution:

…………………………………80
1.5% waste extraction, ……… x 2 = 1.2% of the original trash has been taken out by
beater.
………………………………..100

(3.6-1.2) = 2.4% trash remains in the mtls, which is delivered from the beater.

…………………………………Original T.C – T.C. in delivered cotton

Cleaning Efficiency = …………………………………………..………………… x 100
……………………………………………………….Original T.C

…..3.6-2.4
= …………… x 100
……..3.6

= 33.3% (Ans.)

How to Find Out the Production of the Blow

Room Line
Blow Room Line:
A section in which the supplied compressed bales are opened, cleaned and
blending or mixing to form uniforms lap of specific length is called the blow room
section. A section in which the supplied compressed bales are opened, cleaned &
blending, or mixing to form a uniform lap of specific length is called the blow
room section. The cleaning efficiency of the blow room is 60 to 65%. This is the
first section of the spinning line for spinning cotton yarn. The number of
machines arranged in a line on series to perform all the functions to form a
uniform lap form cotton bale in the blow room line. How to find out the
production of the blow room line will be discussed below.

How to Find Out the Production of the Blow Room Line

Problem-1:
Find out the blow room efficiency, when

 Cotton trash = 4.5%

 Lap trash = 1.75%
Solution:
We know,
…………………………………..Trash extracted
Cleaning efficiency = ……………………………… X 100%
………………………………………Total trash

……………………………………………………Cotton trash% – Lap trash%

So, Blow room cleaning efficiency = ………………………………………… X 100%
………………………………………………………………..Cotton trash%

………4.5 – 1.73
= …………………… X 100%
…………..4.5

= 61.11 % (ANS)

Problem-2:
Find out beats/inch from the following, When

 Beater r.p.m = 720

 No. of strikes = 16
 Feed roller r.p.m = 24
 Dia of feed roller = 3”
Solution:

………………………………………Beat/min
Beat/inch = …………………………………………………………
…………………….The surface speed of the feed roller

…………..Beater r.p.m X No. of the beater

= …………………………………………………………………
……..Π X Dia of feed roller X Feed roller r.p.m

……720 X 16
= …………………..
……Π X 3 X 24

= 76.43 or 76 (ANS)

Problem-3:
Find out the production of blow room line with 2 scutchers.
It contains,

 Calender roller dia = 7”

 Calender roller rpm = 10
 Efficiency = 40%
 Wastes = 4%
 Lap weight = 1403 yds
Solution:

…….Π X 10 X 7 X 60 X 0.90 X (14/16) X (100-4) X 2

= …………………………………………………………………………….
……………..,,……………..36 X 100

= 555.176 lb/hr (ANS)

Blow Room Production Calculations

Formula with Example
Introduction
The section, where the supplied compressed bale is turn into a uniform lap of a
particular / specific length by opening, cleaning, mixing and blending is
called Blow Room section. It is the first step of spinning. Blowroom consists of
a number of machines used in succession to open & clean the cotton fiber to the
required degree and 40-70% trash is removed in this section. Calculations play an
important role during the process. Some important Blow Room production
calculations with example are mentioned in the following article.

Fig: Blow room section

Some Important Conversion Factors for Blow Room Production
Calculations:

 36 inch = 1 Yard;
 1 Lea = 120 Yards;
 1 Meter = 1.09 Yards;
 1 Pound(lb) = 453.6 Gram = 16 Oz;
 840 Yard = 7 Lea = 1 Hank;
 1 Pound (lb) = 7000 Grains;
 1 Meter = 39.37 Inch;
 1 KG = 2.205 Pound (lb)
Hank or count means the number of 840 yards length that weigh exactly one
pound.

Lap Hank Ranges: 0.0012, 0.0013

Blow Room Production Calculations Formula with Example:

Formula 1: Cleaning Efficiency % = (Waste% in Input – Waste% in

Output) / (Waste% in Input)

Example: The trash content of a cotton as fed to beater 3.2%. The waste

extraction is 1.6% of which 80% is trash. What is the cleaning efficiency?

Solution:

Of the 1.6% waste extraction,

Trash = (80/100) x 1.6 = 1.28% of the trash has been taken out by beater.

3.2 – 1.28 = 1.92% waste remains in the material delivered from the beater.

Here, waste% in Input = 3.2%

Waste% in Output = 1.92%

Cleaning Efficiency = (Waste% in Input – Waste% in Output) / (Waste% in

Input)

= (3.2-1.92)/3.2 = 40% (Ans.)

Formula 2: Beats/inch = (Beater RPM x No of Striker) / (π x Feed

Roller Dia x Feed Roller RPM)

Example: Find out Beats/inch from the following

 Beater RPM = 720

 No of Striker = 16
 Feed Roller RPM = 26
 Feed Roller Dia = 3”
Solution:
Here, Beats/min = Beater RPM x No of Striker = 720 x 16

Surface Speed of Feed Roller = π x Feed Roller Dia x Feed Roller RPM = 3.1416 x
3 x 26

Beats/inch = (720 x 16)/(3.1416 x 3 x 26) = 47.011 ≈ 47 (Ans)

Formula 3: Waste% = Waste x 100/Input

Example: 80 Bales of cotton each of 167kg are being fed daily in a 2

scutcher blow room line. Actual production per 2 scutcher per day is 12000 kg.
Calculate the total quantity of waste throughout whole blow room line & waste%.

Solution:

Here, Input = 80 x 167 = 13360 kg

Output = 12000 kg

Waste = 13360 – 12000 = 1360 kg

Waste% = 1360 x 100/13360 = 10.18% (Ans)

Formula 4: No of Bales/Day Fed = (Input (kg/day)) / (Wt. of per bale

(kg))

Example: The production per scutcher per hour in a 2 scutcher blow room line
is 325 lbs. Waste from whole blow room line is 700 kg/day. Calculate the no of
bales required per day for given blow room line. (1 bale = 167 kg)

Solution:

Here, Waste = 700 kg

Output = 325 x 2 x 24/2.205 = 7076.4 kg/day

Input = 7075.4 + 700 = 7776.4 kg/day

No of bales/day fed = 7776.4/167= 47 bales. (Ans)

Formula 5: Production Per Scutcher per Day = (Output (kg/day)) /
(No of Scutcher)

Example: 65 bales of cotton are being fed daily in a blow room line consisting of
2 scutchers. The blow room is to be kept stopped for one hour after each shift for
maintenance, if waste% is 6%, then what will be the production per scutcher in a
day (in kg/hour), while 1 bale = 165 kg.

Solution:

Input = 65 x 165 = 10725 kg.

Waste% = 6%

Waste = 10725 x 6/100 = 643.5 kg

Output = 10725 – 643.5 = 10081.5 kg/day

Production per scutcher per day = 10081.5/2= 5040.75 kg (Ans)

The machine keeps running = 21 hour

Production in kg/hour = 5040.75/21 = 240.03 kg/hour (Ans)

Formula 6: Blow Room Production Per Hour = π x D x G x Efficiency x

Waste%

Example: Calculate the machine production. Here, scutcher m/c RPM is 300,

Roller diameter is 8” and m/c efficiency is 80% within waste% = 5. [Lap Hank =
0.0012]

Solution:

Here,

 Machine RPM, G = 300

 Roller Diameter, D = 8”
 Efficiency = 80% =80/100
 Waste loss = 5% = (100-5)/100
 Lap Hank = 0.0012
M/C Production = π x D x G x Efficiency x Waste%

= {3.1416 x 8 x 300 x 80 x (100-5) x 60} / (100 x 100) inch/hour

= (3.1416 x 8 x 300 x 80 x 95 x 60) / (36 x 840 x 100 x 100) yards/hour

= (3.1416 x 8 x 300 x 80 x 95 x 60) / (0.0012 x 36 x 840 100 x 100) lbs/hour

= 9474.67 lbs/hour (Ans)

Formula 7: Lap Hank = (Length in Hank) / (Weight in Pound)

Example: If lap weight is 15 oz per yard. Find out the lap hank.

Solution:

We know, Length in hank = (Length in Yard) / 840 = 1/840

Weight in Pound = (Weight in (oz)) / 16 = 15/16

Lap Hank = (1/840) / (15/16) = 0.0012 (Ans)

Formula 8: Production Per Shift = (π x D x G x Efficiency x Waste% x

No of Scutcher machine x 60 x shift) / (36 x 840 x Hank)

Example: Calculate the production of Blow room with 2 scutchers if

 Calendar Roller Dia = 7”

 Calendar Roller RPM = 10
 Efficiency = 60%
 Wastes = 4%
 Lap Hank = 0.0012
 Shift = 8 hour
Solution:

Here,

 Calendar Roller RPM, G = 10

 Calendar Roller Diameter, D = 7”
  Efficiency = 60%
 Waste loss = 5%
 Lap Hank = 0.0012
Production Per Shift =(π x D x G x Efficiency x Waste% x No of Scutcher machine
x 60 x shift  )/(36 x 840 x Hank)

= {3.1416 x 7 x 10 x 60 x (100-4) x 2 x 60 x 8} / (36 x 840 x 0.0012 x 100 x 100) lb

= 3351.04 lb (Ans)

Formula 9: Production Per Shift = π x D x G x Efficiency x Waste%

Example: Bottom calendar roller diameter = 7”, RPM of B.C.R = 10, weight of

every yard lap is 12 oz, efficiency = 75% and waste% = 5%. Find out the
production of B/R per shift. [Shift = 8 hour]

Solution:

Here, B.C.R dia, D = 7”

B.C.R RPM, G = 10

Efficiency = 75% = 0.75

Waste = 5% = (100-5)/100 = 0.95

Weight of every yard lap = 12 oz, i.e., 12 oz/yard

Production per shift =π x D x G x Efficiency x Waste%

= (3.1416 x 7 x 10 x 0.75 x 0.95 x 2 x 12 x 60 x 8 ) / (36 x 16 ) lb

= 1566.88 lb (Ans)

Formula 10: No. of Laps Per Day = (Output Lap(kg/day)) / (Weight of

One lap (kg))

Example: 80 bales of cotton are being fed in a blow room line daily. If the pure
weight of cotton per bale is 170 kg and waste% of blow room line is 5%. What will
be the weight of cotton lap received per day from scutcher? Calculate the no of
laps prepared per day if the weight of one lap is 20 kg.

Solution:

Input = 80 x 170 = 13600 kg

Waste% = 5% = 0.05

Waste = 13600 x 0.05 = 680 kg

Output = 13600 – 680 = 12920 kg/day (This is the cotton lap received per day)

No of Laps/Day = (Output Lap(kg/day)) / (Weight of One lap (kg))

= 12920/20 = 646 Laps (Ans)

Production Calculation of Blow Room 

* 1 lb = 16 ounce = 7000 grain = 453.6 gm. 
* 1 Metric ton = 2204 lb. 
* 1 kg = 2.2046 lb. 

Problem-1: 
A lap contains 2% trash after processed in B/R having the cleaning efficiency of 80%. Find the trash % in
raw cotton. 

Solution: 

We know, 

                                    Trash remains after processing 

Cleaning efficiency = ……………………………………… 
                                                Total trash 

                2% 
=> 80 = ..........................
              Total Trash
  
=> Total Trash = 2/100 x 80  
=> Total Trash = 2.5%. (Ans.) 

Problem-2: 
Bottom calender roller dia = 7 inch, rpm = 10 & wt. of every yds lap is 12 oz and cleaning efficiency 75%.
Find out the production of B/R per hour. 
Solution: 

                                      3.14 x 7 x 10 x 60 x 75 x 12 

Production/hr of B/R = ………………………………
                                               36 16 x 100 

= 206.06 lb (Ans.) 

Problem-3: 
If lap length constant is 720, then set the change pinion for 40 yds lap. 

Solution: 

                             lap length constant 

Change pinion = …………………...… 
                                  lap length 

    720 
= ……….. 
    40 

= 18 T (Ans) 

Problem-4: 
If lap wt. is 15 oz per yds, find the hank. 

Solution: 

               1 yds x16 ounce 

Hank = ……………...........……. 
              840 yds x15 ounce 

= 0.0012 hank. (ANS) 

Problem-5: 
If lap wt. – (a) 15 lb/yds, (b) 15 lb/m, (c) 15 grain/yds, (d) 15gt/m, (e) 15gm/yd, (f) 15gm/m. Find the hank. 

Solution: 

                   1 yds x16 lb 

a. Hank = ………………….. = 0.0000793 hank. (Ans) 
                  840 yds x15 lb 

                     1 m x1 lb 
b. Hank = ………........…. 
                  840 yds x15 lb 

      1.1 yds x1 lb 

= ……………………….. 
    840 yds x15 lb 
= 0.0000873 (Ans) 

                   1 yds x 7000 grain 

c. Hank = ………………................ = 0.55 (Ans) 
                  840 yds x15 grain 

                  1 m x 7000 gr 

d. Hank = ………….........…… 
                  840 yds x15 gr 

    1.1 x 7000 

= …………………
     840 x15 

= 0.611 (Ans). 

                  1 yds x 453.6 gm 

e. Hank = ……………..………. = 0.036. (Ans) 
                  840 yds x15 gm 

                 1 m x 453.6 gm 

f. Hank = …………………….. 
                840 yds x15 gm 

    1.1 x 453.6 

= …………………
      840 x15 

= 0.0396. (Ans) 

Problem-6: 
Find the no. of lap per hour in scutcher m/c of Bottom calender roller dia = 7 inch, rpm = 12, efficiency
80%. Lap length 40 yds. 

Solution:                                    π x 7 x12 x 80 x 60 

Production of m/c = ………………………… yds 
                                         36 x 100 

= 351.85 yds. 

                    351.85 
No. of lap = ………… 
                       40 

= 8.79 = 9 (ANS) 

Problem-7: 
Find the no. of lap per hour in scutcher m/c of Bottom calender roller dia = 7 inch, rpm = 12, efficiency
80%, lap wt. 14 oz/yds. 
Solution: 

                      3.14 x 7 x12 x 0.80 x 60 x 8 x14 

Production = …………………………..............…. lbs 
                                       36 x16 

= 2461.76 lbs 

   2461.76 
= ……………. metric ton 
     2204 

= 1.117 metric ton. (Ans) 

Problem-8: 
If in a xsutcher m/c, rpm of B.C.R. is 10, dia 7 inch, lap wt. 12 oz/yd. Find the production/hr at 90%
efficiency. 

Solution: 

                      3.14 x 7 x10 x12 x 60 x 90 

Production = ………………………...……. lbs 
                               36 x 16 x 100 

= 247.275 lbs (ANS) 

Problem-9: 
Production of B/R line with 2 scutchers if B.C.R. dia = 7 inch, rpm = 10, Efficiency 90%, wastes 4%, lap
wt. 14oz/yd. 

Solution: 

                      3.14 x 7 x10 x1x 60 x 90 x (100 - 4) x 2 x14 

Production = ………………...................................……………. lbs 
                                         36 x16 x100 x100 

= 553.896 lbs. (Ans) 

Problem-10: 
Calculate production/he of a B/R line if, r.p.m. of B.C.R. = 14, Dis = 18 cm,, lap hank = 0.0012, efficiency
80%, no. of scutcher = 2. 

Solution: 

                       3.14 x18 x14 x 60 x 0.80 x 2 

Production = …………………………..........…. lbs 
                        36 x 2.546 x 840 x 0.0012 

= 822.2 lbs. (Ans) 
Problem-11: 
Find the B/R cleaning efficiency, if waste in Raw cotton = 6%, waste in sliver = 0.4%. Carding, cleaning
efficiency 75%. 

Solution: 

                                                   waste in lap - waste in sliver 

Carding cleaning efficiency = ………………………..………. X 100 
                                                             waste in lap 

             x - 0.4 
=> 75 = …….... x 100 
                x  

=> x = 1.6%. 

                                            6 – 1.6 
B/R cleaning efficiency = ……...… x 100 
                                               6 
= 73% (Ans.) 

Problem-12: 
The trash control of feed cotton is 3%. After passing the beater 2% waste is extracted, of which 15% is
good fibre, what is the cleaning efficiency of the beater? 

Solution: 

                                  100-15 
2% waste extraction, ……..… x 2 = 1.7% of the original trash has been taken out by beater. 
                                    100 

(3-1.7) = 1.3% trash remain in the mtls, which is delivered from the beater. 

                                    Original T.C - T.C. in delivered cotton 

Cleaning Efficiency = …………………………….........……….. x 100 
                                                     Original T.C 

   3-1.3 
= ………. x 100 
      3 

= 56.66% (Ans.) 

Problem-13: 
Find out beats/inch from the following data- Beater r.p.m. = 720, no. of striker = 16, Feed roller r.p.m. =
24, Dia of feed roller = 3 inch. 

Solution: 

Beats / min = Beater r.p.m. x no. of striker 

= 720 x16 no.s 
= 11520 no.s 

Surface speed of feed roller = πDN 

= 3.14 x 3 x 24 
= 226.08 

                         11520 
Beats / inch = ………………. 
                        226.80 

= 50.96 (Ans.) 

Problem-14: 
The trash content of a cotton as fed to Beater 3.6%. The waste extraction is 1.5% of which 80% is trash.
What is the cleaning efficiency of the beater? 

Solution: 

                                       80 
1.5% waste extraction, ……… x 2 = 1.2% of the original trash has been taken out by beater. 
                                      100 

(3.6-1.2) = 2.4% trash remain in the mtls, which is delivered from the beater. 

                                     Original T.C - T.C. in delivered cotton 

Cleaning Efficiency = …………………………………...........….. x 100 
                                                     Original T.C 

   3.6-2.4 
= ………….. x 100 
     3.6 

= 33.3% (Ans.)