Fabric consumption is one of the most important calculations in bulk T-shirt manufacturing. Polyester fabric is often purchased by kilogram while garments are planned by pieces, so costing teams need a reliable link between GSM, usable width, garment size and marker efficiency.
Why Consumption Changes
The same T-shirt can consume different fabric when GSM, DIA or open width, size ratio, seam allowance or marker layout changes. Higher GSM increases garment weight, while poor marker efficiency increases waste even when the pattern is unchanged.
Practical Calculation Logic
Start with the area of all garment pattern pieces, convert that area into weight using finished GSM, then adjust for marker efficiency and production allowances. Tubular knits should be calculated using usable DIA/circumference; open-width fabrics should use actual usable width after edge loss.
Key Inputs
- Finished GSM after relaxation
- Usable width or DIA
- Approved pattern area for each size
- Order size ratio
- Marker efficiency
- End loss, defect loss and remnant allowance
Step-by-Step
- Confirm actual GSM and width.
- Prepare patterns for every order size.
- Build a marker with the real size ratio.
- Measure marker length and efficiency.
- Convert marker fabric area into kilograms.
- Add realistic cutting and defect allowances.
- Compare planned consumption with pilot-cut results.
Common Mistakes
Using one value for all sizes, ignoring collars or ribs, relying on nominal GSM, and adding a generic wastage percentage without factory data can all distort costing.
Final Thoughts
The most accurate consumption figure combines actual bulk fabric data with a production marker. Tracking planned versus actual kilograms per piece is the best way to improve future costing.
Need Help Planning Polyester Fabric for Bulk Garment Production?
Send Walrus – Yes India Can your garment type, GSM, DIA / width, colour, quantity and end use. We can help shortlist suitable polyester fabric options for bulk production.
Call / WhatsApp:
+91 90472 77722
+91 90420 77722
Website: yesindiacan.in
