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Costing • 11 April 2026 • 14 min read

Warp & Weft Formula Handbook: Weight And Cost Per Meter

Complete formula guide with worked logic for converting yarn units, calculating warp/weft weight, and converting weight into per-meter cost.

// Interactive Formula Lab

Warp + Weft Weight and Cost Simulator

Adjust construction and yarn inputs to see how weight and cost change instantly. This follows the same logic used in the AERA TEX calculator.

Warp Inputs

Weft Inputs

Warp Weight / m

66.000 g

Weft Weight / m

55.440 g

Warp Cost / m

₹15.58

Weft Cost / m

₹12.86

Formula Snapshot

tex(warp) = 100.00 / 9 = 11.1111
warp weight (g/m) = ends × tex / 1000 = 5400 × 11.1111 / 1000 = 60.0000 (before shortage)
weft length (m/m fabric) = ppi × 39.37 × width(m) = 72.00 × 39.37 × 1.6002 = 4,536.0000
total yarn cost / m = warp cost + weft cost = ₹15.58 + ₹12.86 = ₹28.44

Unit Definitions You Must Lock First

Denier represents grams per 9000 meters and tex represents grams per 1000 meters. These are direct systems.

Ne is an indirect count system based on 840-yard hanks per pound; higher Ne means finer yarn.

  • tex = denier / 9
  • tex = 590.5 / Ne
  • Ne = 590.5 / tex

Warp Weight Formula (Per Meter Fabric)

If total ends are known, warp weight per meter before shortage is: ends × warp_tex / 1000.

Then apply shortage factor: warp_weight_with_shortage = warp_weight_no_shortage × (1 + shortage/100).

  • Warp cost / m = (warp_weight_with_shortage / 1000) × warp_rate_per_kg
  • Keep warp shortage separate from weft shortage

Weft Weight Formula (Per Meter Fabric)

First compute picks per meter: ppi × 39.37. Then convert width to meters and get weft length inserted per meter of fabric.

Weft length per meter = picks_per_meter × width_m. Weight follows: weft_weight_no_shortage = weft_length_per_meter × weft_tex / 1000.

  • weft_weight_with_shortage = weft_weight_no_shortage × (1 + weft_shortage/100)
  • weft_cost_per_meter = (weft_weight_with_shortage / 1000) × weft_rate_per_kg

Total Yarn Cost And Final Cost

Total yarn cost per meter = warp_cost_per_meter + sum(all_weft_cost_per_meter).

Final ex-GST cost = total_yarn_cost + khata_kharch + any process overhead to be included in costing model.

Formula Validation Checklist

Use this quick check before final quote: confirm unit conversion visible, shortage stream-wise, and rates updated from latest board.

Always compare one sample run with actual production issue data to calibrate assumptions.