How do calculate the yarn consumption of a Yarn dyed t-shirt?

Learn Apparel Merchandising, Learn Fashion design.
Today we will learn how we can book the yarn for bulk dyeing.

Suppose, you receive a yarn dyed t-shirt order from buyer. Details as below

Style: 100% cotton, Single jersey, 160 gsm yarn dyed round neck t-shirt.

Color:  Beige/Navy (only one combo)

Quantity: 10,000 pcs (in four sizes, S, M, L & XL)

Stripe: Beige 7 cm & Navy 1.5 cm (Total 8.5 cm)

Body length: 73 cm

Sleeve length: 19.5 cm

½ Chest: 52 cm

Consumption: 2.78 kgs/dozen (considering total wastage 18%) you may use this for pricing. Normally the wastage of yarn dyed garments depends on styling. 

Normal wastage for yarn dyed:

Dyeing (yarn) wastage: 6%

Knitting wastage: 3%

Wash wastage: 5%

So, you should need 116 kgs yarn to produce 100 kgs fabric

But be careful, during the bulk yarn booking you should booked the yarn based on the consumption you got by using pattern & marka. Some time I saw buyer asked for match the body stripe with sleeve then the cutting wastage become more than 5%.

We know the body length is 73 cm

Where, beige color stripe is 7 cm

And Navy color stripe is 1.5 cm

Then total length of one repetition is 8.5 cm

So, we need total (73/8.5) = 8.58824 repletion to complete a body (but here we will count 9 repetition for cutting & sewing wastage.)

So, total sum of Navy stripe will be (1.5 cm X 8.58824) = 12.8824 cm

And total sum of Beige color stripe will be (7 cm X 8.58824) = 60.1177 cm

So, 12.8824 cm + 60.1177 cm = 73 cm (total body length)

Now we just calculate the percentage of each color in a body

Navy color percentage in the body will be

= (12.8824 ÷ 73) %

= 17.65 %

= (60.1177÷73) %

= 82.35 %

= 17.65 + 82.35

= 100 %

So, now if the consumption is 2.78 kg

Then

Navy color will be = 0.49067 kg ( 2.78 kg X 17.65% )

And Beige color will be = 2.28933 kg ( 2.78 kg X 82.35% )

In this above way you can booked the yarn

Hope everything is clear to all.

Thanks & best regards

Bipul