Printing and dyeing technology: there is no way to go without continuous improvement

Looking back at the Ministry of Industry and Information Technology of the previous period announced in 2010, the printing and dyeing elimination of backward production capacity list, the government's positive policy is undoubtedly good news for those who want China to improve energy efficiency. At the same time, the trend of polarization in the printing and dyeing industry will become more apparent. At present, the printing and dyeing enterprises with advanced technology and large scale will have a lighter day and the competition faced by small and medium-sized printing and dyeing companies will become very fierce.
A series of effective measures is to ensure that the backward production capacity of enterprises included in the list of eliminated backward production capacity is shut down before the end of September 2010. However, how to find a way out in determining the turning point of life and death? Become the problem facing the printing and dyeing enterprises. Whether it is from the development of previous years or the development of the future, printing and dyeing companies must make a fuss about technological improvement, which has become a safe and stable way out.
The timely adjustment of the continuous update is the best policy. According to the announcement of the Ministry of Industry and Information Technology, the backward production capacity that 201 companies in the printing and dyeing industry need to eliminate has reached 3.81 billion meters in printing and dyeing cloth. Relevant data show that in the first half of this year, the total output of printing and dyeing cloths in China was 20 to 30 billion meters, and the annual output of printing and dyeing cloths in China was 60 to 70 billion meters. Based on this calculation, the outdated printing and dyeing capacity will account for about 6% of the actual demand for printing and dyeing cloth in China.
Judging from the previous rules, some market analysts believe that this adjustment is more detailed, and that the elimination policy will be implemented directly into the enterprise. On the one hand, it is more conducive to the implementation and supervision of the policy. On the other hand, it can also be considered in conjunction with the specific conditions of the enterprise. Avoid "across the board." On the next day after the Ministry of Industry and Information Technology released the list of eliminated backward production capacity in 2010, the reporter noted that in the list, which company's equipment should be eliminated, it also noted that there are three companies that have eliminated the list. It was only in the telephone communication that this trinity was not three yuan, but only the same name. According to the reporter's further understanding, the three yuan in the list is a small and medium-sized printing and dyeing company. The Sanyuan Holding Group Company, which has been eliminating the backward production capacity for a long time, has been performing high-quality equipment and has ensured the production capacity and R&D. The ability to maintain a good development trend.
In a follow-up interview, the reporter found that Sanyuan Holdings has invested 180 million yuan in actively introducing the latest international equipment, eliminating old equipment with high energy consumption and high pollution, and researching and promoting new energy-saving and emission-reduction technologies to provide hardware protection for energy conservation and emission reduction. Xinyuan, Tianyu, Tiancheng, and Xinsheng, the companies of the Zhejiang Sanyuan Holding Group, introduced the "THEN airflow dyeing machine" in batches, reducing the dye bath ratio from 1:10 to 1:3.
It is understood that the airflow dyeing machine uses air as the sole medium to drive the fabrics, and does not require the assistance of water or other devices. The water is only used for dyeing, so it can be dyed at a low bath ratio. For example: cotton fiber bath ratio of about 1:4, chemical fiber about 1:2 to 1:3 atomized dye liquor, so that the dye bath does not have to spray directly on the fabric, to avoid the strong water jet fabric while increasing the dye penetration into the fabric fiber Inside. Due to the low bath ratio, the consumption of auxiliaries, salts, and alkali chemicals can be greatly reduced. The special washing system (VPR) can be used to wash the side row, providing 180 liters of clean water per minute for washing, high flushing efficiency, and consumption. Reduced water consumption, 50% less water than conventional dyeing machines. Due to the small amount of water, the time for water inlet, drainage, heating, cooling and other processes is also reduced, shortening the time of the entire dyeing process and shortening the dyeing time. As the overall time is shortened, the power consumption is calculated to be lower than that of the conventional flow dyeing machine.
The bath ratio changes less than two parts. The dyeing liquor is atomized and then gently carried by the air to the fabric. It does not damage the fabric. It also allows the dye to penetrate into the fabric fibers more easily. At any time, it can be drained at high temperature. When draining, the fabrics are all drained. Can keep running. After two years of actual operation, the results of the field investigations of Tiancheng and Xinyuan, two companies owned by Sanyuan Holding Group Co., Ltd., were found to have been effective recently. It was decided to continue to introduce them to replace traditional high-energy-consuming dyeing cylinders.
Equipment update still needs new technology to follow up. The reporter also learned from the interview that Sanren Holding’s subsidiary companies, such as Hualun Printing and Dyeing, Jimei Printing and Dyeing, have all introduced automatic drip dispensing systems and digital printing machines. , Properly shorten the pre-processing processes and other processes, both to save energy and increase production efficiency. SAMURA rotary screen printing process can greatly save washing water. Paint printing and inkjet printing, reclaimed water recycling technology, printed nickel net recycling technology, etc., can greatly reduce energy waste and printing and dyeing wastewater discharge. They also invested 30 million yuan to install waste gas desulfurization and desulfurization equipment, cooling water recycling system, the existing 11 boiler flue gas waste heat and steam generated for recycling.
Japan's stereotyped machine waste heat recovery devices introduced from Jimei and Tiancheng can save about 15% to 25% of fuel and significantly reduce CO2 emissions.

Emissions. At the same time, the company's total thermal oil boilers installed a total of 9 sets of waste heat utilization devices, a total price of 3.5 million yuan, each set can save 6 tons of steam / hour, and save 140 yuan per ton of steam. Introduced advanced equipment such as Japan KYOTO liquid ammonia finishing and Airo air softener. Reduce the use of alkali, water, additives and softeners. The above-mentioned projects are all put into operation at present, and the effect of energy conservation and emission reduction is obvious.
The numbers can tell everything. The Sanyuan Holding Group Company only eliminated one old transformer, saving 20,000 KW of electricity annually. Eliminating the use of heat-conducting oil furnaces, flue gas waste heat, and waste heat recovery and utilization can save 13,000 tons of standard coal annually. At the same time, Sanyuan Holdings actively develops and promotes new energy-saving and emission-reduction technologies, the “cold-pile” pre-treatment technology, cold-pile dyeing technology, and short-flow wet steam dyeing technology used in cotton and linen products, as well as automated dosing systems and digital The use of printing technology has significantly reduced product energy consumption and water consumption.
It is not difficult to see from the meaning and principle of the automatic control of Jimei Printing and Dyeing in the Sanyuan Holding Group Company that the changes brought about by good equipment and technology are significant. The control of drying moisture regain in the dyeing and drying process can be achieved by controlling the drying temperature. For the drying device heated by steam, the drying temperature is controlled by controlling the steam supply. Therefore, controlling the steam supply of the drying cylinder is to control the moisture regain of the cloth.
The control of the moisture regain in the dyeing and drying process is related to three important indicators: product quality, production efficiency and energy cost. The reduction of energy costs is mainly aimed at avoiding over-bake. They have shown in practice that the control of falling moisture regain in the automatic drying process is more economical than dropping the moisture through the hand test. First, relying on equipment to digitize and automate production operations, workers control production quality indicators. Ability can be programmed and standardized, otherwise there is no standard for evaluation. Second, the result of proceduralization and standardization is that waste can be avoided, quality can be guaranteed, and production efficiency can be rationalized.
Therefore, the control of the moisture regain is very important. On the one hand, excessive drying will inevitably result in energy waste. On the other hand, from the pre-processing to the finishing, the implementation process of all dyeing and finishing processes, the moisture regain of the fiber is one of the physical characteristics that affect the success or failure of the process. Changing the moisture regain can greatly change the processing characteristics of the fiber, such as singeing, mercerizing, dyeing, fixing, pre-shrinking, calendering, nap, setting, etc., and the moisture regain data is reasonable and uniform to quality. And quality and stability play a decisive role.
After a closer look, some small and medium-sized printing and dyeing companies have basically lost their production capacity after eliminating obsolete production capacity and have no choice but to close down. Some companies can rely on advanced equipment and relatively stable market efficiency to continue their production capabilities. The printing and dyeing enterprises that have survived and can develop healthily in this large-scale phase-out will have to continuously adjust their thinking and improve their production process in the future.