Fabric Consumption

The quantity of fabric needed for making a garment is called fabric consumption for costing. It is difficult to know the actual consumption before completion of marker planning but we can get an approximate fabric consumption from sample.

Fabric consumption is calculated by two process :

1. From marker ( it is more accurate)
2. From measurement or mathematical system ( it is approximate)

How to calculate fabric consumption from marker?

For example, if we have got 12 pcs marker and we know that markers needed fabric is 25 yds and one time we lay 200 ply. So how much time to lay and what is the actual fabric consumption for 1000 dozen of garments?

Solution :

One time lay, we can get, 200 X 12 = 2,400 Pcs.

Here, total garments, 1000 dozen = 12 X 1000 = 12,000 Pcs.

Lay time = 12,000 ÷ 2,400 = 5 times lay.

Fabric consumption for 1000 dozen garments = 5 X 200 X 25 = 1000 X 25 = 25,000 yds.

If wastage is 3% then actual fabric consumption = 25,000 + 3% = 25,000+750 = 25,750 yds..

International Fabric Width :

Internationally fabric having five types of width for  woven fabrics 35”, 40”, 45”, 50”, 60”.

International Size Grading :

Infant baby = 1-2-3 years, Size : 1-2-3

Toddlers = 4-5-6 years, Size : 4-5-6

Boys & girls = 6-16 years, Size : 6-8/S, 9-11/M, 12-14/L, 15-16/XL, 16+/XXL .

Basic Information Relevant to Consumption :

1. Measurement with technical specification
2. Style description
3. Fabric description
4. Fabric length or weight and width
5. Washing shrinkage.

Fabric consumption per dozen of a full shirt:

Considering medium size (M) for calculation-

1. Body Section:

(body length+allowance) X (1/2 chest+allowance) X 2

= ( 74cm+5cm) X (55cm+5cm) X 2 = 79cm X 60cm X 2 = 9480 sq. cm.

1. Sleeve Section:

(sleeve length+allowance) X (arm hole straight+allowance) X 2 X 2

=(65cm+4cm) X (23cm+3cm) X 4 = 69 cm X 26cm X 4 = 7176 sq. cm.

1. Collar & Collar Band:

(collar band length+allowance) X (collar band+collar point+allowance) X 2

=(41cm+3cm) X (3cm+7cm+4cm) X 2 = 44cm X 14cm X 2 = 1232 sq. cm.

1. Pocket:

(pocket length+allowance) X (pocket width+allowance)

=(14cm+3cm) X (12cm+2cm) = 17cm X 14cm = 238 sq. cm.

1. Extra Yoke:

(shoulder across+allowance) X (yoke height+allowance)

= (48cm+4cm) X (11.5cm+4cm) = 52cm X 15.5cm =806 sq.com.

Now fabric consumption per shirt will be,

A+B+C+D+E = (9480+7176+1232+238+806)sq.cm =18932sq.cm=18932÷127=149.07cm=1.49m =1.5m/Pc.

Size Rato:

S = 2X1.48 m = 2.96 m

M = 3X1.50 m = 4.50 m

L = 3X1.52 m = 4.56 m

XL = 2X1.54 m = 3.08 m

XXL =2X1.56 m =3.12 m

Total = 18.22 m/dozen.

Costing per dozen of shirt:

1. Fabric cost = 18.22 mX $ 1.64 = $ 29.88
2. Accessories cost  = $ 5.50
3. Washing cost = $ 1.50
4. Dyeing cost = $  50
5. Cutting & Making charge  = $ 15

Total manufacturing cost                 = $ 101.88

.profit 10%                                          = $ 1.19

Commission 5%                                  = $ 5.09

Selling price per dozen of shirt = $ 108.16

Fabric consumption of a polo shirt:

Considering medium size (M) for calculation-

1. Body Section:

(back length+allowance) X (chest circle+allowance)

= ( 30.75”+2”) X (48”+2”) = 32.75” X 50” = 1637 sq. inch.

1. Sleeve Section:

(sleeve length- ½ across shoulder+allowance) X (arm hole straight+allowance) X 2 X 2

=(20.75”-10.5”+1.5”) X (10”+1.5”) X 4 = 11.75” X 11.5” X 4 = 540.5 sq. inch.

Now fabric consumption per shirt will be, A+B = 1637+540.5 = 2177.5 sq. inch.

=2177.5X6.45=14048.36 sq.cm.=1.40sq.m

Size Ratio:

S = 2X1.38      = 2.76 sq.m

M = 3X1.40     = 4.20 sq.m

L = 3X1.42      = 4.26 sq.m

XL = 2X1.44    =2.88 sq.m

XXL = 2X1.46 = 2.92 sq.m

Total fabric = 17.02 sq.m/dozen.

Fabric consumption=17.02 X170 (gsm)=2893.4 gms = 2.9 kg/dozen.

Costing per dozen of shirt:

1. Fabric cost (2.9 kg X $10.00) = $ 29.00
2. Collar cost/dozen              = $ 8.00
3. Accessories cost = $ 3.50
4. Washing cost  = $ 3.00
5. CM charge = $ 5.00

Total manufacturing cost                 = $ 48.50

.profit 10%                                          = $ 4.85

Commission 5%                                  = $ 2.43

Selling price per dozen of shirt = $ 55.78

Fabric consumption per dozen of a trouser:

Measurement for medium (M) size:

Waist                          = 32”

Length                        = 40”

Width of crotch point = 13”

*Pocket length           = 12”

*Pocket width            = 7”

Fabric consumption per trouser = ( length+allowance) X (width+allowance) X 4

= ( 40”+3”) X (13”+3”) X 4 = 43” X 16” X 4 = 2752 sq. inch.

Lenth of fabric(width of 50”) per trouser = 2752÷50 = 55.04 inch.=1.53yds.

It is also required to calculate pocketing fabric requirement. As per design two front pocket needs pocketing fabric is calculated as follows-

=(pocket length+allowance) X (pocket width+allowance) X 4

=(12”+2”) X (7”+2”) = 14” X 9” X 4 = 504 sq.inch.= 504÷45 =11.2” = 0.31yd/Pc

= 0.31 X 12 = 3.73yds/dozen = 3.73 X 0.91 = 3.40 m/dozen

Fabric consumption per dozen trouser as per size ratio:

Waist size	No. of  Pcs	yards
32	2	1.53 X 2 = 3.06
33	2	1.55 X 2 = 3.10
34	3	1.57 X 3 = 4.71
35	3	1.59 X 3 = 4.77
36	2	1.61 X 2 = 3.22

Total fabric consumption                  = 18.86 yds = 18.86 X 0.91= 17.16 m/dozen

Costing per dozen of trouser:

1. Fabric cost (17.76m X $2.00)                          = $ 35.52
2. Pocket fabric cost/dozen( 3.40m X$1.00)  = $ 8.00
3. Accessories cost                          = $ 5.00
4. Washing cost                           = $ 4.50
5. CM charge                          = $ 20.00

Total manufacturing cost                 = $ 73.02

.profit 10%                                          = $ 7.30

Commission 5%                                  = $ 3.65

Selling price per dozen of shirt       = $ 83.97