Technological Innovation In Production Of Colored Spun Yarn

1 to multi fiber blended, multi color direction development

Over a long period of time, the production of colored spun yarn has a high dependence on cotton.

With the development of non cotton fiber production and variety at home and abroad, its application in colored spun yarn is increasing gradually, but its utilization ratio is still low.

China still accounts for more than 80% of the total.

Due to the high price of cotton in China and the decline of cotton quality after dyeing, how to reduce the use ratio of cotton and increase the use of non cotton fiber in colored spinning is an important topic in the technological innovation of colored spinning.

In recent years, Zhejiang colored spinning enterprises have made initial achievements in developing colored cotton yarn with various non cotton fibers.

Such as Huafu and Bailong two color spinning leading enterprises, respectively, cooperate with the difference fiber manufacturing company of Zhejiang Hong Qiang and Shanghai Defu Lun, develop modified bamboo carbon colored polyester fiber and functional differential polyester fiber, and produce distinctive colored yarn, some have directly cooperate with brand clothing to enter the high-end market at home and abroad.

At home and abroad, chemical fiber manufacturers have developed "cotton imitation" and "super cotton" varieties in the modification of polyester fibers. There are also many varieties of modified polyester. They have profiled sweating fibers, high shrinkage fibers, cationic dyeable fibers, hollow fibers and so on. At the same time, the strength of modified polyester is higher than that of cotton fibers. The modified differential polyester and colored cotton blend can complement each other and make up for the defects of low strength.

For example, the 18.5tex multi component knitted colored spun yarn developed by Yiwu Hengsheng color spinning company is blended with three kinds of raw materials, such as colored cotton, Australian wool and cashmere, so that the yarn has soft, skin friendly, comfortable handle, strong resilience and good thermal insulation properties. It can be used as the first choice yarn for high-grade knitted underwear, and is universally welcomed by knitting enterprises.

In addition, the colored cotton sub fine fine cotton multi component blended yarn developed by Wenzhou Li Tian Group has formed three series of 28.0tex, 19.7tex and 18.5tex. The yarn has moisture absorption, breathability and cool style, and is the best yarn for summer knitted garments.

In conclusion, the development of high quality natural fiber multi component blended yarns such as wool, silk and nylon will be a trend of high-end yarn development with various differentiated and functional fiber blended yarns, which should be highly valued and closely watched by color spinning enterprises.

Through technological innovation, expand the proportion of non cotton spinning, and strive to pass 2 years of ~3 product structure adjustment, so that the amount of cotton in the color spinning to 50%~60%.

2 improve quality, reduce labor and update equipment.

(1) the advanced automatic mixing machine is used to replace the artificial small mixing method.

The technology is Huafu color spinning company's research and development success. First, the various colors and cotton are released by batch and then the principle of solid cotton mixing is applied. The raw materials of different colors and varieties are evenly mixed and packaged, and then the cotton bag is grabbed on the bag grabbing machine. The cotton can be saved and the cotton can be evenly mixed according to the ratio and color.

(2) using a simple blowing carding unit, the loose cotton layer is pported to the carding machine directly in the natural state, which can effectively reduce the burden of carding, reduce fiber damage and improve the quality of cotton sliver.

The carding self leveling mechanism can control the weight difference of the output strip online and reduce the unevenness of long and short segments.

It can be flexibly adjusted according to the batch size of colored spun yarn, and a cotton cleaning production line is equipped with 4 ~8 carding machines.

(3) use high efficiency comber.

Most of the colored spun yarns are dyed with combed cotton net and then mixed with cotton. They are no longer restricted by small batch and multiple varieties. When using comber, the control power of the comber is much higher than that of the A series, so the combed cotton web short rate is lower, the output is 3 times ~4 times of the A ~4 comber, and the number of each unit can be reduced to 5 ~6.

(4) at the end of the road.

The self leveling device can automatically and automatically control the length and length of the sliver, and make the yarn unevenness and evenness significantly improved.

In addition, the self leveling technology of drawing frame can reduce one drawing frame from 3 to 2, and the weight of the drawing will be reduced correspondingly.

Replacing the traditional A roving roving machine with the advanced suspended spindle roving machine can increase the production efficiency of single machine by more than 30%, and the 10000 sets can be reduced from 4 to 3, achieving constant tension winding, eliminating the details of defective goods produced by switch cars, and improving the quality of yarn.

(5) spinning process should be gradually adopted with automatic doffing long machine.

Because of the particularity of the production of colored spun yarn, the ability of workers to stand is lower than that of spinning colored yarns.

At present, the collective doffing long machine manufacturing technology and the use of experience are ripe.

In the long run, the colored spinning enterprises have been promoted slowly by the shackles of small quantities, varieties and high frequency of renovation.

By adopting collective automatic doffing, the doffing workers can be reduced by more than 50%, and ten thousand ingots can save 12 ~16 people.

Adopting automatic doffing car on conventional spinning frame can reduce labor intensity and reduce doffing labor by more than 1 times, and its retrofit cost is relatively low, and is being gradually promoted.

(6) winding process is the most frequently used process in color spinning, which accounts for 70%~80% of spinning workers. Therefore, reducing the winding work is also the focus of attention.

The pallet type automatic winding machine is a new technology that is matched with the spinning machine. The yarn replacement and the winding yarn are all made use of intelligent technology, resulting in further reduction of winding work. Each worker can take care of 3 ~4 units with a tray type automatic barrel machine.

Color spinning enterprises should expand the use of pallet type automatic winder.

Because of the frequent modification of the colored spinning enterprises, the thin thread couplet is not suitable for use.

In short, through the popularization and application of the above spinning technology and equipment, the quality grade can be further improved and the use of workers can be significantly reduced.

A preliminary analysis of the 19.7tex yarn in colored spinning enterprises can reduce the employment of 10000 spindles to 100 people, which can be reduced by more than 50 people compared with the current ten thousand spindles.

3 speed up the popularization and application of new spinning technology.

(1) adopt new ring spinning technology, such as compact spinning.

Duan color composite spinning and so on.

For example, the AB yarn produced by siro spinning and the colored spun yarn produced by compact spinning are superior to the traditional ring spinning yarns because of their strength, strip and Mao Yu and so on. Therefore, they can be used for high quality fabric production yarn, and the fabric can be characterized by fine, even, neat and smooth style.

For example, the yarn dyed by colored yarn is fed by double roving or three roving, and the roving enters the main draft area and the draft separately respectively by continuous pmission, discontinuous speed change or pause, and effective mixing is done in the main draft area, and then the yarn is spun into ribbon yarn after twisting and winding.

The fabric made of colored yarn has irregular flow pattern, and has long color distribution and unique style. It can be applied to knitted and woven fabrics. All kinds of knitted underwear and T shirts are popular among consumers.

In addition, through proper pformation of the ring spinning frame, the color spinning yarn, such as colored spun yarn, dot yarn, rib yarn, corrugated yarn and dust yarn, is developed and produced. The color spinning is not only innovative in the color mixing technology, but also has marked changes in the shape and structure, greatly changing the appearance of the traditional color spinning yarn.

(2) new spun yarn used in colored spun yarn is rotor spinning and air-jet vortex spinning.

Compared with the ring spinning, the spinning process is short, the production efficiency is high, the labor is saved, and the products are distinctive.

Two kinds of spinning technology were used to produce yarn by cotton sliver, which reduced the plant area, energy consumption and employment. The spinning speed of the new spinning was much higher than that of the ring spinning, the spinning speed of rotor spinning was 100m/min~150m/min, and the speed of the vortex spinning was 350m/min~400m/min, which was 5 times ~8 times and 15 times ~20 times of the ring spinning respectively.

The new spinning equipment generally adopts intelligent technology, such as automatic joint, automatic generating, automatic changing, automatic conveying of empty cylinder and yarn, greatly reducing the labor intensity of workers, and the reduction of 50%~75% per ton yarn compared to ring spinning. This is of great significance to solve the problem of many employment in color spinning enterprises.

In view of the new spun yarn forming mechanism and yarn structure, except for a slightly lower strength and a little hard handle, other single strong irregularity, weight irregularity, Mao Yushu and so on are better than ring yarns.

In particular, the yarn produced by jet vortex spinning has good appearance and good pilling resistance. It can be used for high-grade knitting and woven fabrics, and its price is over 20% higher than that of ring spinning.

Therefore, the color spinning enterprises should actively adopt new spinning technology, improve product grades, save energy and reduce consumption, and reduce employment.