Yarn needed for a knit order

In a real company

Knit merchandiser, yarn procurement

For knits you buy yarn, not fabric. You work backwards from the garment weight through cutting, dyeing and knitting losses to know how much yarn to book.

Key ideas

• Finished fabric = garments × garment weight × (1 + cutting wastage%).
• Greige fabric = finished ÷ (1 − process loss%) — dyeing loses weight.
• Yarn = greige ÷ (1 − knitting loss%).

Formula

Finished fabric

= Qty × Weight × (1 + Cutting%)

Greige

= Finished ÷ (1 − Process loss%)

Yarn

= Greige ÷ (1 − Knitting loss%)

Worked example

20,000 T-shirts weighing 210 g each. Cutting wastage 8%, dyeing/process loss 10%, knitting loss 2%.

1. 1Finished = 20,000 × 0.21 × 1.08 = 4,536 kg
2. 2Greige = 4,536 ÷ 0.90 = 5,040 kg
3. 3Yarn = 5,040 ÷ 0.98 = 5,142.9 kg

✅ Book about 5,143 kg of yarn.

Common mistakes

• Multiplying by (1 + loss%) instead of dividing by (1 − loss%) for process losses.
• Using the sample garment weight without the size ratio.
• Forgetting rib / collar fabric.

Quick quiz

Answer 2 of 3 correctly to complete the lesson.

1. 1. Finished fabric 900 kg, process loss 10%. Greige?

   990 kg1,000 kg810 kg909 kg

2. 2. Why divide by (1 − loss%)?

   It is easierThe loss is a share of the input, not the outputBuyers require itTo include GST

3. 3. Order: 1,000 pcs × 200 g, no losses. Fabric?

   200 kg2,000 kg20 kg200,000 kg