The number of texturing machine companies has surged in recent years. In fierce competition, market prices have become more transparent. The cost advantages of traditional textile companies have gradually declined, and profit margins have been further squeezed. Coupled with the increasingly stringent policy environment, most textile companies are struggling to survive in the cracks. Whoever controls costs well will have a competitive advantage. Being poor means thinking about change, which requires our textile enterprises to change their concepts and explore new development paths. Instead of staying behind closed doors, why not go out and take a look. To this end, starting from today, the editor will gradually collect some relatively good cases in the textile industry and share them with everyone, so that in the era of sharing economy, we can also share technology, share management, and share business models.
What I want to share with you today is A textile factory in northern Zhejiang has developed from one texturing machine in 2014 to four texturing machines and more than 300 water-jet looms. It has been producing flat peach, oblique peach and polyester-cotton interwoven pocket fabrics for many years. In fact, there are thousands of companies like this in the textile industry, but just one such company, with its excellent product quality and low-cost management model, achieved sales revenue of more than 80 million yuan in 2016, quickly taking the lead in the industry. level. Then we can’t help but wonder, how does such an enterprise’s products have no characteristics, how can it survive and develop in the increasingly harsh environment? Let’s look for the answer from his texturing workshop and see how they achieve a refined management level through process optimization and equipment transformation and upgrading, focusing on quality and cost control.
01 Equipment scale
The factory originally had 950V type texturing There are 3 machines, 1 30 cubic meter modified piston air compressor (for producing mesh wire), 1 15KW-8 normal pressure screw machine (for texturing machine suction gun), and 4 warping machines. Due to the expansion of scale, a 950V texturing machine was added, and a 110KW-2kg (48 cubic) low-pressure screw machine was purchased. The original 30 cubic piston machine was used as a backup machine. The main varieties produced are network yarns between 60D and 150D.
02 Production process sharing
1. POY texturing process Process
Production equipment: 950V texturing machine, domestic 1.2mm network nozzle, Transva anti-spatter DTY oil agent, Tongkun Hengteng 110dtex/48F semi-matt POY.
Production process: 110dtex/48F semi-dull POY (Hengteng) → raw silk rack → cutter → first roller → first hot box → cooling plate → false twister →Second roller→Second hot box→Networker→Third roller→Filament detector→Oiled roller→Winding→DTY finished yarn.
2. Process parameters
Processing speed 720 m/min, Draft ratio 1.70, speed ratio (D/Y) 1.65, first (H1)/second (H2) hot box temperature 170℃/160℃, wire outlet ratio -6.20%, winding ratio -6.0%, network pressure 0.161 MPa, oiling speed 0.3 rpm.
03 Key process analysis
The quality of the network directly affects the efficiency and quality of weaving. If the network is too light, it will cause warp breakage, reduce weaving efficiency, and form defective fabrics. Excessive network weight leads to increased energy consumption and obvious network points on the cloth surface, which affects the effect and overall style of the cloth surface. For pocket cloth, a good network should be light but not scattered, which is convenient for weaving, but the effect of the cloth surface is that the network is scattered, plump and not transparent.
The original piston air compressor had large compressed air pulses and poor air quality. Although the network nozzles were cleaned once every 10 days, network leakage and network leakage still occurred from time to time. This leads to a decrease in weaving efficiency and an increase in defective fabrics. Although increasing the network pressure can extend the cleaning cycle of the network nozzles, the energy consumption cost will also increase, and the network quality cannot be guaranteed.
The pressure of the screw air compressor is stable and pulse-free, and the air quality is relatively good. The network nozzle is not easy to block. Through the adjustment of the equipment and the cooperation of the process, it can be achieved with a lower pressure. Better web and canvas effects.
1. Network processing technology
When processing low elastic yarn network , the network device is generally installed at the entrance of the second hot box. During the processing process, the greater the tension of the wire, the smaller the vibration produced by the wire under the impact of the high-frequency air flow, and the loosening of the wire and the The degree of rotation decreases, resulting in a decrease in network degree. However, if the yarn tension is too low, it will easily cause the yarn to flutter. The yarn will float into the second roller and cause end breakage, which will affect production.
The editor found that their network device is installed between the second hot box outlet and the third roller, so that the best network processing tension can be obtained by adjusting the wire output ratio. Air compressor pressure to get the best network effect.
2. Residual torque Control
As an intrinsic quality indicator of polyester DTY, residual torque has a great impact on weaving efficiency and speed. The large residual torque makes it easy to tangle during warping on the one hand, and on the other hand when weaving It is easy to get tangled and cause broken ends when the machine is shut down, affecting weaving efficiency and fabric quality; the residual torque is smallOn the one hand, it is not easy to tangle, which can improve the warping efficiency. On the other hand, DTY can make the network lighter in the low torque state. The two complement each other. Therefore, DTY production should effectively control the DTY residual torque.
Between the two rollers and the three rollers, the higher the setting overfeed, the closer the false twist deformed yarn is to heat setting in the relaxed state, the higher the fiber shrinkage, and the internal stress The more complete the relaxation, the lower the curl degree of DTY and the smaller the residual torque.
If you want to get a DTY that suits you, it all depends on the adjustment of the product process. The craftsman needs to have rich operating experience and a good grasp of the overall performance of the machine. He can adjust the process at any time according to product needs. Optimization, thereby producing network low stretch yarn that always meets customer needs.
The picture above shows the residual torque display of 60D/48F finished DTY
04 Comparison of data before and after equipment transformation
Considering the limited gas production of the original air compressor, The air pressure is pulsating and the energy consumption is high. There are high requirements for the cleaning frequency of the nozzles. The factory replaced the air compressor and used a relatively energy-saving low-pressure screw machine. After the replacement, the gas production was stable, the pulse was far away, and the air quality was remarkable. Improved, the network air pressure dropped significantly, the nozzle cleaning cycle was extended, and basically no network leakage occurred.
Through air compressor replacement, pipeline optimization, network nozzle upgrade, and process cooperation, the original network pressure of 2.4bar has been reduced to 1.61bar. After the pressure is reduced, the network effect can still ensure weaving. requirements, and the cloth surface effect is better, and the cost of network processing is greatly reduced.
1. Comparison of gas consumption before and after
The following two tables It is a comparison of the air consumption of the factory before and after. Through comparison, we can find that although a texturing machine was added, the overall pressure dropped by 0.79 bar, and the total air consumption increased by 5.83 cubic meters per minute.
1 Gas consumption before equipment modification
2Gasconsumptionafterequipmentmodification
Air compressor system supply pressure
Gas tank pressure
60D/48F network nozzle pressure
130D/144F network pressure
In order to reduce the pressure drop, the network main pipeline uses galvanized pipes with a diameter of DN200 for gas storage. The inlet and outlet of the tank are both DN200, and the valves are 304 stainless steel full-flow ball valves. For the varieties with the highest pressure, the valve is fully opened, and the air compressor is used to adjust the maximum air pressure. For varieties with low pressure, the air supply pressure is adjusted through the valve. It can be seen from the figure that the air supply pressure of the air compressor is 0.17MPa, the pressure of the air storage tank is 0.169MPa, the pressure of the gas end is 0.161, and the pressure drop along the way is 0.009MPa.
2. Comparison of energy consumption of major equipment
The following is the equipment transformation Comparing the electricity consumption data before and after, the original 3 texturing machines used an average of 56,000 yuan per month in electricity, and the current 4 texturing machines used an average of 44,800 yuan in electricity per month. From the comparison, the energy consumption of each machine is obvious. It has been reduced by 11,200 yuan, and the photovoltaic cost of the four machines has been saved by more than 490,000 yuan in one year, which is equivalent to a BMW car.
1
Power consumption distribution of 3 machines
Note: 324.04*24*30*0.72=168168 yuan/month
2
Power distribution of 4 machines
Note: 345.04*24*30*0.72=179013 yuan/month
3. Optimization suggestions
For larger enterprises, it is recommended to use a more advanced centrifugal air compressor with an air flow of about 80 cubic meters. This machine is used in Vietnam It has been widely used in other places and has a tendency to catch up from behind. Therefore, it is also recommended that those colleagues who are new to join this industry can choose more advanced equipment to directly reach the leading level in this field.
05 Conclusion
In fact, through the analysis of the above aspects, It can give us some inspiration:
First, as long as cost control is good, even traditional enterprises can make a difference. In the era of great waves, at least in the short term, Still maintain a certain competitive advantage.
Second, cost control requires two aspects of work. The premise is the transformation and upgrading of equipment, and the other is the optimization and coordination of processes. No matter how advanced the initial investment in equipment is, there will be no Without technical support and effective management, the results will not be obvious.
Third, for most traditional enterprises, the initial investment has been too large, and transformation and upgrading are relatively difficult. In this era of great waves, it is just a good time for new enterprises to join. Opportunities require more advanced concepts, equipment investment selection, scale control and cost compression from the beginning, refined management, and improved overall operating efficiency. Enterprises that can adapt to market competition in the future must be small and medium-sized enterprises that can respond to market changes at any time.
� Those who make a difference can still maintain a certain competitive advantage in the era of great waves, at least in the short term.
Second, cost control requires two aspects of work. The premise is the transformation and upgrading of equipment, and the other is the optimization and coordination of processes. No matter how advanced the initial investment in equipment is, there will be no Without technical support and effective management, the results will not be obvious.
Third, for most traditional enterprises, the initial investment has been too large, and transformation and upgrading are relatively difficult. In this era of great waves, it is just a good time for new enterprises to join. Opportunities require more advanced concepts, equipment investment selection, scale control and cost compression from the beginning, refined management, and improved overall operating efficiency. Enterprises that can adapt to market competition in the future must be small and medium-sized enterprises that can respond to market changes at any time.
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