Jie Er Shuang: Pay Close Attention To Seven Gap Between Domestic And Foreign Dyeing And Printing Industry

1. Dyeing chemicals and auxiliaries

Dyeing chemicals and auxiliaries are one of the key factors affecting the brightness and color fastness of printing and dyeing fabrics, and also the main source of pollution caused by dyeing and printing.

The use of many dyes and chemicals is limited in the case of "ecological" characteristics.

Therefore, high quality and environmentally friendly dyes and chemicals are important components of the cost of high-grade printing and dyeing fabrics.

China's dyestuff industry has been developing rapidly in recent years, and the quality of dyestuff products, especially its output has been greatly improved.

However, printing and dyeing enterprises generally feel that the dye uptake and chemical stability of domestic dyes are lower than those imported from internationally renowned manufacturers.

Some indicators of color fastness of domestic dyes, such as fastness to heat sublimation and fastness to perspiration, have not yet reached international standards for export orders.

Imported fabrics are commonly used for export of high-grade fabrics in China.

The main difference lies in the poor quality of commercialization.

Some pigments have wide particle size distribution, irregular particle shape, and 5% to 10% loss in dyeing.

The purity is not high enough.

Contains more impurities.

The quality and purity of the dyestuffs are related to the impurities. The contents of impurities, salts and even heavy metals in the dyestuffs of our country are relatively high, and the composition is complex. Under the same dyeing conditions, these impurities can affect the dye uptake, color and fastness, and also pollute the environment. This is related to the fact that the manufacturing technology of vat dyes is relatively outdated, new technology is applied less, raw material control is not strict, and detection means are backward.

Varieties can not meet the needs of the market.

Some kinds of dyes in China have the effect of embrittlement, and some dyes have wet denaturation, thermal denaturation and finishing agent discoloration.

Dye additives affect shade.

Foreign dyestuffs solve the problem of dyeing freshness and fastness from structure. In order to reduce costs, many additives are added to affect color and color fastness in China.

Some dyes interact with the adjunct binder at high temperature ironing.

A weak acid dye, G, a famous dye manufacturer in Switzerland, was forgotten and stored in a warehouse of a Beijing company for 23 years.

After the discovery, I wanted to use it again, and I was afraid of the problem. The dye manufacturer and the new manufacturer were tested for the same color fastness, and the color samples of two silk fabrics were found to be exactly the same regardless of color or depth.

A printing and dyeing enterprise in Guangdong mainly produces bedding products exported to Europe and America, so that he recommends domestic flame retardant finishing agents, and requires that the flame-retardant effect can be washed for 200 times.

After trying out two well-known brand products, they failed to meet the requirements of customers. However, they had to use the very expensive imported products designated by the dealers.

2, equipment gap

The wet and short dyeing process of reactive dyes can save energy by 30% to 40%, the dyeing and fixing rate is increased by 10% to 30%, and the dyeing fabric's brightness is still very high.

At present, the key problem to be solved in China is to develop sensors that can detect the parameters such as chromatic aberration, alkali concentration and hydrogen peroxide concentration. This requires physical, chemical, electronic and other cross industry technical cooperation.

Timely obtaining these parameters can adjust and control the production process, greatly improve the dyeing and finishing quality, reduce consumption, improve the production rate, and achieve higher reproducibility and process stability.

(1) pre-processing aspects

Development of mercerized concentrated alkali liquor and desizing and scouring of light alkali liquor concentration, bleaching hydrogen peroxide concentration and efficient, short process equipment on-line detection and control system.

The field total control system has been widely adopted in foreign countries, and China has just begun.

In addition to some conventional projects such as speed, temperature and liquid level measurement and control in China, special online monitoring projects are still in the initial stage in China, such as poor automation control and poor program control. Online monitoring has not really solved; remote monitoring and fault diagnosis technology is not yet available in China.

In the automatic measurement of dyes and chemicals, the metering system of Benin grid will continuously calculate and formulate the flow rate of various chemical materials according to the actual dosage required, and automatically supply the materials according to the ratio according to the setting and actual value.

The automatic metering system of German Asia Technology Co., Ltd. is a complete automation integration system for dyeing and finishing plants.

China's quantitative titration and automatic feeding are not matched. These largely restrict the improvement of the mechanical and electrical integration level of dyeing and finishing machinery, and also affect the final processing quality of the fabric.

In terms of dyeing, the detection and control of temperature and humidity in the wet short steaming continuous dyeing process, as well as the control of dye ratio pump and rolling rate, are not enough.

In line with the chromatic aberration monitoring device, the svalite online chromatic aberration analyzer of Israel EVs company adopts video information processing technology. It can detect the color of the left, right and right sides of the fabric and carry out chromatic aberration analysis at various angles. The speed of the adaptable vehicle is 150m/min and the maximum gate width is 1950mm. The Mahlo differential control system of the Mahlo (manor) Company in Germany has continuously measured the liquid volume of the whole fabric after the fabric rolling mill is continuously measured through the pverse movement spectrophotometer on the entire cloth.

In the aspect of photoelectric automatic weft alignment, the technology of Munro (Mahlo), Italy (biancd) and sel-ren (Japan) is an advanced technology in the world. In particular, the weaving and weaving of the photoelectric weft of the Italy company can be monitored at the same time, and a complete closed-loop photoelectric weft control system is formed.

The photoelectric weft knitting in Japan is intelligent sensor, and each detection head has independent CPU processing.

(two) finishing aspects

The humidity of the drying room of the cloth is developed, the temperature and humidity of the exhaust gas discharged from the drying room and the moisture regain of the cloth are detected and controlled in real time, so as to achieve the quality and stability of the heat setting printing and dyeing products, save energy and reduce exhaust emissions.

The key parts of the domestic dyeing and printing equipment are not passed, such as the drain valve of the stereotype machine can leak in a few days, and the bearing is also worn out in two days.

Some enterprises reflect that the Taiwan sanding machine is not ready to import Italy grinding machine.

The homemade dyeing machine basically passed the customs, but a few imported mills were imported.

Cold pad batch dyeing machine can not be done, mainly because of the proportion pump.

After sale service for domestic printing and dyeing machines is not enough. It can not be called at any time.

3, innovation (Design) gap

Less investment in R & D

According to the results of the 2004 national industrial census, the proportion of R & D investment in clothing industry accounted for only 0.16% of the sales revenue, only 0.3% of the textile industry, 0.47% of the research and development of the chemical fiber industry, and 0.65% of the top 10 enterprises in printing and dyeing competitiveness.

In the 2006 Beijing international fabric exhibition, most of the European exhibitors invested in R & D is 5-10%, and our fabric industry, on average, is 0.3% above average.

Most of the enterprises below scale have no R & D capability.

In expanding reproduction, the printing and dyeing industry must focus its attention on improving core competitiveness, dilute the volume of expansion, and enhance the content of innovative technology, so as to increase the added value of products, cope with the impact of international trade friction and market uncertainties, and participate in international competition.

The output value of printing and dyeing new products accounts for a low proportion of total industrial output value.

The output value of printing and dyeing new products accounts for a low proportion of total industrial output value.

In 2003, the output value of new products in the printing and dyeing industry accounted for 4.3% of the total industrial output value, reaching 60-80% abroad.

In 2005, textile competitiveness evaluation of innovation competitiveness index, printing and dyeing enterprises participating in the average innovation input 0.95%, product value-added rate 101.56%, innovation performance 35.56%; the top 10 enterprises average innovation input 0.65%, product value-added rate 111.49%, innovation performance 42.75%.

Digestion and absorption, low re creation rate

More than 80% of our technological pformation investment is used to import technology and equipment, and only 9%, 5% and 3% are used for patent licensing, after-sale service and consultation.

The ratio of digestion and absorption to re creation is 1:0.08.

That is to say, spend 1 yuan on the introduction of equipment, spend only 8 cents to digest, absorb, and recreate. The result is that the same technology and equipment are repeatedly introduced, resulting in the introduction, backwardness, reintroduction and then lag behind.

The ratio of digestion and absorption and re creation in Japan and Korea is 1:5 - 1:8, that is, to spend 1 yuan to introduce technology and equipment, to spend 5 yuan -8 yuan for re creation, and the introduction of equipment is limited to 1 units.

Technological development stepped on the shoulders of giants, and achieved leaping development.

Without market research, market demand is the source of innovation and the foundation of scientific positioning.

The decision making basis of R & D and production in China generally follows the feeling, without market research input and market research team.

Abroad, there are huge market survey investment and team. All decision bases must be made according to market feedback information.

For example, the American Cotton Association has a large survey team, and makes detailed analysis and scientific prediction on the market demand of garments and home textiles in the United States and around the world (including China).

According to the lifestyle survey conducted by the US Cotton Corp, consumers who bought functional finishing products accounted for 54%, 31%, 25% and 4% of wrinkle resistant, water repellent, antifouling and antibacterial products respectively, indicating that 96% of them were anti wrinkles, 94% were water repellent and 93% were antifouling.

It shows that the main direction of the functional finishing of cotton clothing in the US market should be wrinkle resistant, water repellent and antifouling, with antibacterial activity accounting for about 4%.

For example, according to the "2001~2005 Western Europe bioactive textiles (bio-activetextiles) market" in 2004, the d&k consulting company showed that antibacterial, fungal and mites accounted for 3% of the textile sales, of which 70% were antibacterial and 30% were against mites.

The usage accounts for >6% of the total bedding, accounting for <2% of the total garment.

The above us and European market survey shows that although the functional products have high technical content and added value, they account for about 4-5% of the total market demand.

Clothing is in great demand.

It is a wrinkle resistant, water repellent and antifouling product; the demand for home textiles functional products is higher than that of flame retardant and antibacterial products.

Market research shows that the input of functional products should be controlled by a certain proportion, otherwise there will be oversupply.

Imperfect technological innovation system

Industrial innovation capability is not simply a superposition of innovation capability of individual enterprises, but a wider range of deeper social cooperation division of labor.

At present, the integration ability of the upstream and downstream industry chains in China is relatively poor, and there is no integrated innovation system between industry, University, research, industry, and industry chain. The public innovation platform such as R & D center, information center, testing center, marketing center and demonstration base established in the industrial cluster is not perfect. The division of labor within the industrial cluster is not clear and the product convergence is serious, resulting in vicious competition of the products, forcing enterprises to reduce as much as possible in the raw material adoption, processing equipment, processing technology and so on, which affects the quality improvement and innovation development of the printing and dyeing products.

Lack of R & D personnel

In 2006, competitive data analysis showed that in the eight industries of cotton, wool, silk, hemp, chemical fiber, printing and dyeing, knitting and clothing, the number of R & D institutions accounted for only about 2% of the total number of enterprises.

The shortage of R & D funds and researchers directly affects the level of R & D results, and the problem of fewer original products is more prominent.

In many enterprises, the number of new products reaches three digits every year, and the proportion of new products output value in the total competitiveness is 16% to 45%, and individual industries even reach 80%.

Although the category and quantity of new products are relatively large, most of them only change in process, pattern, color and so on. Even if the "new degree" product is relatively high, most of them are follow up, trailing and imitation products.

Original products with independent intellectual property rights, high technology content and strong competitiveness are few and far between.

4, management gap

Our country already has the hardware that processes the world advanced level dyed cloth, but the profit margin of the product is very low.

Output growth and profit growth are out of sync.

It shows that there is a gap in the core competitiveness of innovation, brand awareness, management and information technology, and the first-class equipment can not play a role.

No sampling inspection for grey fabric

Some enterprises do not set up grey cloth spot check procedure. Sometimes, an order should be made of grey cloth of many manufacturers. Due to the difference of batch number and defect of grey fabric, it is inevitable that printing and dyeing processes will cause color difference.

Example: Guangdong tinkling cat harmful dye event.

No semi-finished products inspection

Except for a small number of enterprises, most of the products are not detected in wool, whiteness and pH value, and the quality of printing and dyeing products is difficult to guarantee.

Many printing and dyeing factories only have proofing rooms without physical indicators laboratory.

Product inspection is not standardized.

Many enterprises have no finished product inspection workshop, only a few cloth inspecting machines. Some enterprises even set up the machine directly under the setting machine or the steaming machine. The main problem is that they are genuine products, and no concept of first rate.

Only Middle East and African customers who are not very demanding, such as European, American and Japanese orders, do not meet the requirements.

Clothing factories often claim for shrinkage or color fastness.

Weak process control in production process

There are not many on-line detection devices. Except for foreign enterprises, joint ventures and large enterprises, most of them do not have the spot check system. The lack of seriousness in production process control and execution process will cause many problems such as color and light inaccuracy, color difference between front and rear, left and right sides, cylinder difference and stain.

Poor quality of personnel

The operators of the new plant do not know what the "wool effect" and "mercerized barium value" are.

The inspector only knows the defect line. As for the requirements of the hanging line, such as the interval length, the distance between the head and the tail, and the requirement of placing the code, it is not clear.

Some simply do not connect.

Ask them whether they know the "four point system" and most of them do not know.

5, brand gap

Many printing and dyeing enterprises export products to order processing, most enterprises lack their own brands and control of export marketing channels, due to multiple intermediate links, resulting in a large number of profits loss.

With the further development of the reform and opening up, the pace of internationalization of the domestic market is accelerating. In addition to the high-end brands abroad, the second line brands abroad have also entered China, and the Chinese brands are facing great challenges to the control of the domestic market.

Beijing's 35 high-end stores, 60% are imported brands, top stores more than 90% are imported brands.

Shanghai Huaihailu Road operates 2 brands, and 60% is imported.

Now the access to service trade has entered a new stage. If the high-end brands are localized in China, if they do not speed up the pformation of growth mode, China's brand will be digested.

Opening brings us opportunities for development, learning opportunities, but also brings market risks. If we do not strengthen brand building, we will lose the dominant position of our own brands in our domestic market.

6, information management gap

Transnational allocation of resources, pnational production and pnational sales are important signs of socialized production development in the era of globalization.

To adapt to the pnational division of labor, printing and dyeing industry must take the development of information network technology as an important foundation and implement ERP management and marketing of production.

In order to effectively shorten the procurement chain, production chain, retail chain.

At present, our country is used to the traditional "three existing pactions", that is, spot, cash and spot trading.

It can not integrate into the pnational supply chain network system, is not suited to the rapidly changing world market and domestic market, and has a high position in the field of innovation and rapid response, which affects the textile industry's pformation of growth mode and weakens the international competitiveness of products.

7, energy consumption and resource recycling gap

The annual water intake of the printing and dyeing industry is 3-5 tons / 100 meter cloth, which is 2-3 times that of the same industry abroad. The standard coal consumed by printing and dyeing is 1.8 times that of the international advanced level, and the amount of waste water discharged accounts for sixth of the total in the country, accounting for 80% of the textile industry.

The composition of printing and dyeing wastewater is complex and the treatment cost is very high.

Although in recent years, the state and local governments attach great importance to printing and dyeing cleaner production and sewage treatment, the rate of wastewater reuse is <10%, which is at the lowest level in various industries. It has endanger the implementation of China's "sustainable development" strategy.

The recycling of terephthalic acid and ethylene glycol from the polyester fiber alkali reduction process and the separation of sea island fiber fabrics from the chemical fiber products and the recovery of light alkali from the mercerizing process of pure cotton products have not been recovered by many factories, and the problem of "saltwater" emission from reactive dyeing is also a problem that needs to be solved and studied.

Although emissions accounted for only 5%, the COD impact was 55%.

With the rapid growth of the national economy, the problems of energy supply shortage and ecological environment are becoming more and more serious.

Economically developed areas and cities have limited the development of dyeing and processing capacity.

Therefore, developing circular economy, improving the efficiency of resource utilization, and saving energy and reducing consumption have been related.

Survival and development in the future.

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