How To Adjust Dyeing Process In Order To Save Energy And Increase Efficiency

The price is also rising as the international energy situation changes.

The implementation of the new labor law has further increased the human cost of enterprises.

The cost pressure of enterprises is bigger and bigger, the profit space is getting smaller and smaller, especially the textile printing and dyeing industry.

Enterprises can not change the objective environment. To survive, we must focus on the interior of the enterprise, further adjust the process, save energy and increase efficiency.

Around this goal, we have made adjustments and applications in the following areas, and achieved certain results.

Application of high solid reactive dyes.

In general, the fixation rate of reactive dyes is between 50% and 70%. After dyeing, a large amount of dyes are left in the dye bath. Some of them are hydrolyzed dyes. The more dye the color is, the more residual dyes are.

In view of this situation, some high lift reactive dyes were selected. They have two vinyl sulfones and one chloro three azine. They all have excellent high suction rate and high lifting force, and hydrolytic dyes are easy to remove.

For example, dyestuff black uses about 9% of reactive dyes, and only 5% of the reactive dye with high dyeing power is selected.

The dyeing depth can be achieved in the case of small amount of material, which can reduce 2~3 times of washing and reduce the discharge of sewage.

Dyeing tons of dark cloth can save about 130 yuan.

Pretreatment and scouring and bleaching for one bath pretreatment can save water fee of 50 yuan /t, save electricity cost 40 yuan /t, save steam cost 200 yuan /t, improve the dyeing rate of fabric treated with enzyme before treatment, save about 0.5% 60min, save some time of 60min, reduce the amount of pretreatment additives, simplify the process and shorten the process flow; enzyme scouring does not require high temperature, high pressure, strong base and strong acid to catalyze decomposition reaction: not only high efficiency but also no damage to fabric, weightlessness is about 3%, soft handle, strong damage, biological enzyme is easy to completely biodegraded, biological scouring enzyme does not cause environmental pollution.

The pretreatment of medium and light coloured products is dull in color and not clean in cottonseed husk.

The application of one bath dyeing process, multi component fiber (such as more than 3 kinds of fiber) fabric dyeing, conventional dyeing process to multi bath dyeing, not only time-consuming energy consumption, but also more sewage.

Through experiment analysis, selection of auxiliaries and process adjustment, one bath two step or two bath dyeing should be controlled as far as possible to achieve maximum energy saving, emission reduction and consumption reduction.

For example, there are 4 kinds of fibers in the fabric: polyester, cotton, viscose and nitrile. First, dyeing acrylic fiber at 30min at 98 degrees, then cooling it to 60 degrees, adding precipitation inhibitor to 15min, then adding disperse dyestuff to L30 degrees.

The application of acid soap lotion is usually alkaline soap soaping agent. After dyeing, it needs 2~3 washing and acid soaping.

The acid soap soaping agent is used to reduce the over acid part and reduce the once washing. The dyeing cost of the dark products is greatly reduced, which is about l00 yuan /t.

The success rate of dyeing was improved once.

To improve the dyeing success rate, reduce the repair rate, reduce energy consumption, reduce pollution and improve production efficiency, there are generally the following measures: strengthening process monitoring, strictly carrying out the process, monitoring the equipment status in time, testing the dyes and auxiliaries of different batches in time, improving the process according to the actual situation, making the production consistent with the laboratory; improving the dyeing pass rate through the proofing, resampling and lofting of the new orders; rechecking the production process according to the different batches of yarn, adjusting the production process in time, and avoiding the problem of color modification due to the color difference of the raw materials.

Through above

Adjustment and application, we successfully passed the difficult first half of 2008.

Although all kinds of costs continue to rise, we have digested part of the cost increase factors and achieved better economic results under the premise that the price of dyeing and finishing products has not been adjusted.