Spreading loss is the loss of fabric outside the marker. The various fabric losses outside the marker can be broadly classified into different groups, namely ends of ply losses, ends of piece losses, edge losses, splicing losses, remnant losses etc, which are discussed below:
1. Ends of Ply Losses:
End of ply loss occurs when the spreader reaches the end of the marker and the fabric must be cut from the roll or folded back for the return lap. End loss occurs at each end of a spread. Losses may be 1 to 2.5 inches at each end, and for a spread of 100 ply, the waste can be significant. The shorter the spread, the higher the ratio of loss. Caution is needed to minimize the amount of fabric allowed at the end of a spread and to cut the fabric straight. A slanted end cut can waste fabric at both ends of a spread. The amount of end loss varies with the spreading mode and equipment. Excessive end loss and careless spreading can create inventory shortages and poor utilization that will ultimately increase production costs.
2. Ends of Piece Losses:
In textile industry fabrics are produced and processed in different batches. During finishing these fabric ends are stitched together for continuous operation, which makes the fabric ends unsuitable for use due to marks or distortions created. The affected lengths should be as less as possible, i.e. only a few centimeters. The end of piece loss varies from 0.5-1% of the total fabric usage, because the fabric length is not exact multiple of the marker length. This loss could be minimized if the average length of the pieces that are purchased is increased. The ends of piece losses cannot be eliminated completely, but it can be controlled by establishing clear procedures for splicing and processing of the remnants.
3. Edge of width Losses:
In normal practice during marker planning, the width of the marker is kept a few centimeters less than the edge-to-edge width of the fabric. The marker is made according to the usable width of the fabric. The usable fabric width depends upon the quality of the selvedge, the consistency of fabric width, and on the precision of edge control during spreading. Let the fabric edge-to-edge width is 100 cm, and the marker width is 3 cm less than the fabric width. The edge loss is 3%. If the fabric edge-to-edge width is 150 cm, the loss is 2%. Thus wider width fabrics have other benefits besides improved marker efficiency. This simple calculation reveals that the fabric loss outside the marker is very sensitive to the edge waste allowances. Great care is needed to ensure that the allowance is not excessive. Width variation in fabrics must be controlled alongside the edge allowances.
4. Splicing Losses:
Splicing is the process of overlapping the cut ends of two separate pieces of fabrics so that spreading can be continuous. The distance between the splicing lines influences the amount of fabric waste. The splicing losses may vary up to 5% of the total fabric usage. Splicing is necessary as one roll of fabric is finished and a new roll is taken into use. Also during spreading, there may be some objectionable fabric faults, which are need to be removed by cutting the lay at the fault point.
5. Remnant Losses:
Remnants may be generated when short lengths of material are left over after the completion of a lay, and are returned to the stores. All remnants are put aside and cut separately with short markers. The markers produced for remnant lays normally have a lower utilization than the production marker, because the reduced number of garments’ parts limit the opportunity to moving around the patterns for satisfactory result in the marker. There may be single garment marked if the garment pieces are large, but more garments may be marked if the garment pieces are small. Remnant loss is unavoidable but may be reduced depends on piece length, the higher the piece length the lower the remnant loss.
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