Dyeing plant must read │ dyeing plant profit shrinkage how to reduce production costs

Author: Zhejiang Qiao Seoul Tingting Clothing Co., Liang Jiajun

Summary:

The printing and dyeing factories are currently faced with the dilemma of small environmental pressure and profit space, and they must exercise reasonable control over the cost of dyeing and improve the management level. This paper analyzes the techniques improve the dyeing process (pre-treatment, dyeing, finishing); thermal energy recovery and utilization of the respective steps and equipment processing; sewage treatment and handling cost control; enhanced automation management, reduce labor costs; dyes The cost control and management ; dyeing plant ERP information technology management and other specific measures to improve the competitiveness of dyeing plants.

In recent years, the situation facing printing and dyeing factories is very serious, the production cost is getting higher and higher, and the pressure of competition is increasing.

The main reasons for this status are:

First, labor costs are getting higher and higher, and recruitment is difficult. Employment issues will be one of the important issues that companies face later;

Second, under the market economy, the pattern of the textile industry has changed, the textile industry in Southeast Asia has risen, and China’s large orders have slowly flowed to countries such as Vietnam and India.

Third, the continuous appreciation of the domestic renminbi has affected the profits of export order companies;

Fourth, the government has imposed restrictions on carbon emissions. As pollution discharge control and discharge standards have been raised, the sewage discharge standard in 2013 has increased from 500 mg/kg to 200 mg/kg, which has increased the pressure for energy saving and emission reduction in many printing and dyeing enterprises.

In the face of these pressures, dyeing plants need to consider how to survive and develop.

(1) the strength of the company must first consider the export of capital goods exports into use of the advantages of the current resources and tax policies of Southeast Asian countries, the transfer of production facilities to foreign and domestic factories as a research and development center.

(2) It is necessary to focus on the internal development of the company, continuously develop new products, improve product quality and added value, strengthen internal management, and minimize production costs. Enterprises focus on "two centers, one basic point", that is, customer-centric external, internal employees as the center, a basic point is the cost control.

(3) Create your own brand.

This article from the pretreatment, dyeing, after treatment, energy recovery use, wastewater management, automation management, dyeing material aspects of cost management and CDW IT management, cost management put forward some suggestions for the dyeing factories reference.

1 Process Technology Improvement and Cost Management

Dyeing factories laboratory is key sectors, cost-conscious laboratory cost management, dyeing technicians, determines the cost of controlling the entire dyeing factory. Dyes, additives selection, directly related to the cost of dyes and additives, by dyeing process improvement and innovation, reducing steam, electricity and water consumption of the dyeing process, the production cost can be reduced. Therefore, to control the cost of dyeing factories, we must first start with the cost management of laboratories.

1.1 Pretreatment process technology improvement

1.1.1 Low-temperature practice bleaching technology

Cold-rolled bunkering bleaching, although it takes a long time to cool the bunker, does not require steam and saves steam costs.

Scouring enzyme with cellulase enzyme scouring, scouring at a temperature of 50 ~ 60 ℃, temperature 98 deg.] C instead of the original scouring, saving steam, and the application of scouring enzyme may reduce the burden on wastewater treatment.

1.1.2 Low temperature oxygen bleaching technology

The oxygen bleach is typically hydrogen peroxide to a temperature of at least 9 5 ℃, and low temperature oxygen bleaching aid which can play a role in the bleaching 60 ~ 70 ℃, save energy, reduce the loss caused by oxygen delignification.

1.1.3 Low-temperature silk refining technology

Conventional silk scouring temperature is 90 ~ 95 ℃, low temperature protease scouring with scouring degumming scouring at a temperature of 55 ℃, saving of steam, while also preventing the ashes of silk scouring damage caused by high temperature, but also reduces the stress in sewage treatment .

1.2 Dyeing process technology improvements

Improvement, innovation and technology management staining on cost control has played a significant role.

1.2.1 Refined degreasing and dyeing one-bath process technology

For chemical products (such as nylon, polyester, etc.) and some products regenerated cellulose fibers (e.g., Tencel, modal, etc.), without oxygen bleaching, scouring degreasing can simply, degreasing and scouring can be considered the same dye bath .

Process flow: scouring degreasing → washing → dyeing.

The bath process sequence above three workers synthesized one step, saving two water, steam and power consumption saving refining used, reduce emissions 2/3.

1.2.2 reactive dyes low temperature dyeing process technology

The reactive dye dyeing of cotton and regenerated cellulose fibers is usually carried out at a medium temperature of 60°C, sometimes at 80°C. Currently, low temperature dyeing reactive dyes are mainly two types, one is 40 ℃ staining, as Hai Annuo L thereof reactive dyes; the other is cold batch dyeing reactive dyes at room temperature, although a longer time, but energy saving, cost reduce.

1.2.3 One Bath Dyeing Process of Cellulose Fiber and Polyamide Interwoven Fabric

Regenerated cellulose fibers or cotton / nylon fabrics like a bath dyeing engineering arts, reactive dye choice is crucial. Need to use high temperature neutral fixation of reactive dyes, reactive dyes such as CN Kayaku of Japan, Haiya shipped NF reactive dyes, the reactive dyes Hai Annuo N thereof, which promise security and newly developed type NC Reactive dyes. These neutral fixation of reactive dyes at a low-alkali or alkali-free dyeing conditions the fibers and fixation.

Traditional process: Scouring oxygen bleaching → water washing → heat treatment → water washing → oxygen scavenging enzyme with cotton → hot water washing → acid and after soaping → → washing → dye Jin Lun → water washing → water washing → heat treatment (functional treatment and soft handling) → the cylinder.

A bath dyeing process: Scouring oxygen bleaching → water washing → Enzyme addition After heat treatment → water washing → oxygen cotton / nylon dyeing bath → water washing → water washing → heat treatment.

The dyeing process was reduced from the original 13 steps to 8 steps, shortening the dyeing time, reducing the amount of steam, water saving up to 38.5%, and reducing the discharge of 38.5%.

1.2.4 one-bath dyeing process technology of polyester/nylon/ammonia fabric

Conventional process flow: scouring degreasing → dyeing polyester → washing → reducing cleaning → washing → dyeing nylon → washing → post-treatment.

Improve the process: scouring dyeing polyester nylon with the bath → washing → 60 °C FR Shirts

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