The setting of the dyeing and finishing process is related to various aspects of the company’s manpower, hardware, and environment. In short, it needs to rely on five major factors: personnel quality, equipment, raw materials, dyeing materials, and market demand.
Continuously optimize the production process
Printing and dyeing factories need to consider five major factors when formulating the dyeing and finishing process: Equipment, raw materials, dyes and chemicals, personnel quality and market demand. The type and operation of the equipment determine the tolerance and stability of the dyeing and finishing process. The characteristics of the raw materials determine the key points of the process. The dyeing and chemical factors will affect the process flow. The technical personnel, managers and operators who formulate the process determine the level and implementation of the process. quality etc. It is proposed that in actual production, the process must be both stable and timely adjusted, and the cost performance of each link must be continuously optimized to achieve the process goals to the greatest extent at the lowest cost.
The impact of equipment on process formulation
Currently, process planners’ considerations for equipment mostly include: Three levels: existing equipment of the enterprise; existing equipment that can be modified; and equipment that the market can provide and the enterprise has the intention and ability to increase. These three constitute the enterprise’s equipment status, and the equipment status is the basis for process formulation.
1. The type of equipment determines the tolerance of process development
The basic equipment of cotton-based woven dyeing and finishing enterprises includes: singeing machine, desizing machine, boiling and bleaching combined machine or single oxygen bleaching machine Machines, mercerizing machines, sanding machines, continuous dyeing machines, shaping machines, pre-shrinking machines and quality inspection rolling machines, etc. The basic dyeing and finishing process of cotton woven fabrics is: singeing → desizing → scouring → bleaching → mercerization → (sanding) → dyeing → finishing → pre-shrinking → quality inspection. This process has great limitations in improving product quality and reducing costs.
If a cold stack pre-treatment rolling machine is added to the basic equipment, continuous equipment can be used to safely produce sensitive fabrics that are prone to wrinkles when exposed to moisture and heat. Many corduroy varieties After brushing, the burnt billet can be directly processed by cold stack, deboiling and bleaching. Fabrics that are prone to wrinkle marks in the steamer or fabrics that cannot be processed directly in the combined boiling and bleaching machine can be rolled, deboiled and stacked before continuous boiling and bleaching. This can not only ensure product quality and expand variety adaptability, but also Save steam and improve the utilization efficiency of continuous equipment.
In addition to the basic equipment, a cold pile dyeing rolling machine can be used for small batch dyeing on a continuous pad dyeing machine. Single sample and setting out (because the preparation work is completed through small samples, there is no need to test and set out on the rolling machine); it can improve the consistency of large batches of color sheets (after selecting the dye, setting the head cylinder in place, drying , steam fluctuations and other influencing factors); it can solve the problem of different colors in corduroy fabrics; it can improve the dyeing permeability of thick and tight fabrics, especially for sofa home textiles that require high wear resistance; it can Perform salt-free staining.
In addition to the basic equipment, several sets of jigger dyeing machines can be added to solve the pre-treatment and wrinkled fabric hemming. Dyeing and even soft processing; solve the problem of thick and transparent color processing and small batch processing that are difficult to achieve in pad dyeing and cold dyeing; solve the problem of retaining the three-dimensional sense of concave and convex jacquard fabrics; solve the dyeing processing of other components of blended wool fabrics.
In addition to the main machine, there is a multiple washing machine consisting of a flat washing tank, a J-shaped box and a short steamer. Functional washing machine, you can perform enzyme desizing, cold stack pre-treatment, water washing and soaping after cold stack dyeing, dispersion reduction cleaning, active stripping and repair, etc. on this machine, which greatly enhances the selectivity of the process.
Add several sets of dryers between the scouring unit and bleaching unit of the continuous boiling and bleaching combined machine, which can It can be processed in combination and in sections. Some varieties of singeing can be placed after desizing and before bleaching, which requires one less process than singeing before desizing and then boiling and bleaching, and can better ensure the whiteness of the product.
In short, the flexibility of equipment configuration and process will directly affect the company’s ability to expand varieties and product quality, and it must be long and short Combination, intermittent and continuous combination, and combination of main and auxiliary machines maximize machine utilization and process effects, and enhance the flexibility of process selection.
2. Equipment operation determines the stability of the process
The good operation of the equipment depends on its own quality and routine maintenance.
The quality of the equipment itself is determined by the quality of the host and the quality of accessories. This is the basis for ensuring process quality, and daily maintenance is important for The stability of dyeing and finishing production also plays a very important role. For example, the rubber of the uniform rolling roller is easy to wear and produces left and right color differences; if the ratio pump of cold pile dyeing is not good, the ratio of dyes and additives cannot be maintained, resulting in inconsistent color and light; the temperature of the setting machine is unstable, which will directly affect the quality of elastic fabrics. Door width, elasticity and shrinkage; if the quality of the air pipe connected to the air compressor is not good, it will burst when it is slightly heated, and the machine will stop frequently, causing parking defects. Therefore, in addition to considering the equipment cost for the basic equipment configuration of the printing and dyeing plant, you can also consider choosing Coster’s uniform padding machine, Monforts’ shaping machine and drawing sanding machine to ensure the accuracy of the process and the stability of long-term operation. .
In daily production, rolling must be carried out regularly�Processing technology with little or no water, little or no salt; reducing the leakage, energy consumption, number of samples, and the management level of the automatic control platform for residual discharged materials.
2. Quality requirements promote cost-effective technology
In recent years, increasingly stringent and complex quality requirements have brought higher difficulties to dyeing and finishing companies. In terms of appearance, the product’s smoothness (dead cotton, yarn ends, radish shreds, etc.), color purity (yin and yang sides, surface focus, ring dyeing, etc.), uniformity (exposed bottom, yellow and white sections, stripes, etc.), color difference (plate alignment) The requirements for accuracy, left-center-right color difference, match difference, etc.) are getting higher and higher. In terms of intrinsic quality, more and more color fastness items are required, and the fastness indicators are getting higher and higher.
Therefore, the formulation of the process must be fully considered. For example, if the fastness to soaping, dry rubbing and sweat stains is not up to standard, you can Remedy it by re-washing, treating with additives, etc.; if the perspiration resistance, sun fastness and other indicators are not up to standard, it needs to be stripped and re-dyed with high-performance dyes. Therefore, we must understand the requirements of the order, analyze possible difficulties, select appropriate dyeing materials, and formulate a reasonable process.
3. The market’s individual needs create diverse craftsmanship
In recent years, Tencel fiber, milk fiber, soybean fiber, bamboo pulp fiber, microfiber, moisture-wicking fiber, PTT fiber, polylactic acid fiber, The emergence of various environmentally friendly and functional fibers such as chitin fiber, coupled with the combination of new fibers and traditional fibers, has made multi-component fiber fabrics increasingly popular. Therefore, in recent years, there has been a lot of research on the dyeing and finishing processes of various new fibers and multi-component fibers, and processes such as two-color and flash colors have appeared. However, different components are damaged, yellowed, and shrunk during pre-treatment. The dyes stain each other on each component, and the color fastness is reduced. Different colors and hues are limited, and it is difficult to dye very pure colors of the same color, and the brightness is reduced. This requires the rational selection of fiber combinations and organizational structures when formulating the process, and the rational formulation of the dyeing and finishing process and process conditions based on the characteristics of each component.
In recent years, post-finishing methods have emerged in endlessly, such as frosting, enzyme washing, tie-dying, sandblasting, and ginning. Various processing methods such as coating and coating enrich the appearance of the fabric. The market for functional textiles is also growing, such as waterproof and oil-proof, breathable, easy to remove dirt, anti-wrinkle, easy to care for, antibacterial and health care, flame retardant, antistatic, anti-ultraviolet, etc. These finishing methods will cause changes in the dyeing and finishing processes of other processes. For example, for corduroy fabrics that need to be post-washed, the dead cotton on the fabric surface can be covered to the maximum extent after dyeing. There is no need to re-cook the fabric during pre-treatment, or brush the hair after dyeing; for fabrics that need to be post-processed such as frosting, sandblasting, etc. For fabrics, it is best to use sulfur dyes for dyeing; for fabrics that require no-iron finishing, the front-end processing should retain as much strength as possible; for moisture-absorbing and sweat-wicking fabrics, hydrophilic softeners should be used.
4. The market’s delivery time cost demands a successful process
Whether the textile and apparel industry can quickly provide the required products has become a reflection of the market adaptability of manufacturing companies. Shorter and shorter delivery times require companies to respond quickly when organizing production, with good reproducibility and accuracy the first time. This demand puts forward higher requirements for process design elements, such as equipment, raw materials, dyes, personnel quality and management methods. Therefore, enterprises need to accelerate the transformation of traditional processes and realize automation and intelligence as soon as possible; accelerate the pace of enterprise informatization to improve the scientificity and transparency of management; must stabilize the quality of raw materials; select high-quality dyeing auxiliaries; and improve personnel at all levels. quality, and constantly adapt to the production rhythm of a successful production. </p
