How Can Chaozhou And Shantou Printing And Dyeing Industry Realize The Rebirth Of Nirvana By Intelligent Manufacturing?

In recent years, the printing and dyeing industry has basically maintained a stable operation through structural adjustment and pformation and upgrading. With the decline of printing and dyeing cloth production, economic indicators such as main business revenue and profit have increased, indicating that the development of printing and dyeing industry has changed from scale to quality and efficiency.

However, it is important to note that the printing and dyeing industry still faces many problems while consolidating its development.

Two, the Chaoshan printing and dyeing industry is relatively closed to other printing and dyeing areas, and the customer group is relatively stable. Basically, it is a local customer group, which is developed by relying on the older generation of printing and dyeing people.

At the same time, because it is a high energy consumption, high pollution and labor intensive industry, it brings some pollution.

Three, environmental pressures are constantly escalating, and the implementation of laws and regulations such as new environmental protection law, waste water discharge and atmospheric emission has brought pressure to enterprises.

Development trend of intellectualization

Intelligent manufacturing is the whole life cycle of integrating manufacturing technology and digital technology, intelligent technology and network technology into the design, production, management and service of enterprises. It mainly includes four aspects: intelligent design, intelligent production, intelligent management and intelligent manufacturing services.

The printing and dyeing industry is a technology intensive industry. The process is more complex, the parameters are many, production and management control elements are many, and the significance of realizing intelligence is more important.

The specific role of intelligence in industry has five aspects in the short term.

The first is to reduce labor costs and increase production efficiency; the two is to improve the technological level and management level of enterprises; the three is to raise the level of energy conservation and emission reduction and cleaner production; four, to improve product quality and stability; and five, to improve market response speed and adaptability.

With the continuous improvement of the level of intelligence and the integration with the Internet, intelligent manufacturing will play an increasingly important role in the pformation and upgrading of the industry.

In the entire textile industry, printing and dyeing intelligentization is the most difficult. Not only the connection between pre processing, dyeing and finishing equipment is achieved, but also systems such as spinning, chemical fiber, knitting and other management systems, production systems and equipment automation are completed, and the problems such as dyeing and injection system, dye delivery system, wastewater treatment and emission are solved.

Printing and dyeing intelligent production case

Rongsheng textile

The successful completion and commissioning of Rongsheng dyeing and finishing is a successful example of the pformation from traditional printing and dyeing factory to intelligent chemical plant.

The informatization of management process is different from the ordinary EPR system. Xuzhou Rongsheng textile finishing Co., Ltd. links the management of incoming and offline management with the internal management of production, and connects the data between devices to realize the intellectualization of the internal production system.

Rongsheng in the production process, each device is connected to a computer terminal, small equipment is more than one device to enjoy a computer terminal; large equipment is connected to a single computer terminal.

When the ERP system enters the process, all data can be shared and intelligentized.

In the actual production, only need to brush the production process card, you can know where each vehicle cloth is in the right place and which process it is in.

After the credit card, you can know where the cloth is now and where to do it.

Of course, the process cards can also be used to quickly calculate the workers' output and calculate the monthly piece rate wages.

With the automation of manufacturing process, the intelligent management system of Rongsheng can also automatically pfer the formula to the dye conveying system.

First, select the number of the preparatory dye vat.

Then, the flow card is input into the flow control system, and the process card automatically configures a flow card number after passing the scan code.

Then, the recipe data and production process of the process are automatically displayed.

Finally, after the manual confirmation is correct, data can be sent to the automatic weighing system for actual production.

After the release, the automatic weighing can display the detailed information about the current production.

The whole process is basically completed by intelligent system, greatly reducing the participation of labor force.

Besides the production system, order inquiry is also intelligentized.

When querying an order, you only need to input the corresponding instructions to automatically display the detailed information of the current order.

How many cylinders are put into the order, the location of this cylinder cloth, etc.

In addition, Rongsheng pioneered the introduction of the automatic intelligent weighing system.

In the process of weighing, there is no need for manual labor intervention. The whole process is completed automatically by intelligent equipment.

After the preparation of the dyestuff mother liquor is completed according to the actual requirements, the conveying is carried out according to the actual production requirements. Compared with the traditional weighing and chemical processing methods, the operation process greatly reduces the operation error and improves the preparation accuracy of dyeing chemicals.

Flax flax

Zhejiang Fenglin flax dyeing and finishing Co., Ltd., which is imported from Italy, can not only quickly test the hue component information of the cloth color, but also pmit the color information directly to the automatic proofing system through the Internet of machines. The samples produced are automatically compared with the color of the files, and the system automatically chooses the most matching color dye formulation.

Wynn printing and dyeing

Yongli printing and dyeing is the first imported printing and dyeing ERP system in Shaoxing, and this advanced concept has brought huge dividends to the development of printing and dyeing enterprises. We have been running for 7-8 years on the concept of intelligent printing and dyeing. We have made great efforts from trying to running in and then producing benefits. Now, what I am most happy about is the evaluation of our customers. "After we have seen the intelligent production area of Yongli printing and dyeing, we are surprised to see that the scene is even more shocking than previously reported," Wu always said proudly.

In the dyeing workshop of Yongli dyeing and printing company in Shaoxing, Qian Li Jiang, deputy general manager of the company, is inspecting the dyeing process with several customers from Jiangsu.

An automatic weighing device imported from Italy has attracted customers' attention: because of the chromatic aberration of manual operation, the color fastness will vary greatly. Now, through automatic computer equipment, the error is very small.

Seeing such equipment, Jiangsu customers immediately placed orders for 100 tons of cloth.

The news spread to Wu Yanfang, the general manager, but she had seen a lot of strange things.

Since the relocation of enterprises to the Binhai Industrial Zone, customers who have come to visit will not go back empty handed.

Wu Yanfang said, "I didn't say I had to run second to see it.

Last time, there was a client from Hongkong who visited me, and said to me, this is the one.

Xing Ming dyeing and finishing

The Hsing Ming dyeing and finishing workshop completely changed people's impression of traditional printing and dyeing enterprises. Relying on the opportunity of gathering and relocating, the company built intelligent printing and dyeing factories with high starting points, high investment and high standards.

Based on the new ideas and new cognition of the dyeing and finishing industry in the future, the high level has introduced a series of advanced equipment from abroad through long time industry and market verification, such as Goller of Germany.

In Germany, Then air jet dyeing machine, Fuji gate (Monforts) setting machine in Germany, Galvanin automatic dewatering machine in Italy, Italy Pentek continuous enzyme washing machine, automatic laboratory proofing machine produced by Italy technology Rima (Tecnorama), automatic feeding system and auxiliary automatic conveyor, waste water treatment equipment, packing line, semi-automatic warehouse and whole process digital dyeing process control system are set up in Italy science and technology Rama (Tecnorama) 1 sets.

The new equipment is a fully automated system. It adopts the best production technology and the most advanced technology, uses the dyestuff and high performance auxiliaries with high ecological and environmental protection and high dye uptake. It selects highly efficient, energy-saving and low-carbon automation equipment with the world's leading technology level, and develops and produces low energy consumption, low emission, high added value and hi-tech textile fabrics.

After the use of these advanced equipment and technology, the company's human resources cost has also dropped significantly, reducing the difficulty of employment.

In the international first-class intelligent equipment, we integrate the best production technology and advanced technology, use eco environmental protection, high dye uptake dyes and high performance auxiliaries, and develop low energy consumption, low emission and high added value functions.

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This is a new situation which is actively created by Xing Ming and dyeing and finishing.

Joint hair textile

Lian FA textile invested 36 million yuan to carry out technical pformation of the original dyeing workshop to achieve "machine substitution".

The "dye auxiliaries automatic distribution system" introduced from Italy, and the "central control system of dye vats" developed by dyeing equipment manufacturers, has independently developed the enterprise resource management system (ERP), which constitutes the core of the intelligent dyeing workshop.

Intellectualized "three systems" seamless docking, to achieve the planning tasks, production processes, monitoring and recording data interoperability.

Under the intervention of ERP, all production instructions and process recipes in dyeing workshop will be automatically pmitted to each machine platform through the central control system. The materials will also be automatically distributed to each dyeing machine through the dye auxiliaries delivery system. The central control system will collect every production data of the VAT in real time to ensure that the management personnel are more efficient in controlling information.

Originally, workers first used ordinary scales to dye the dye, then put them into small barrels, and sent them to dye vats for dyeing with a cart. This process is prone to errors in metering, non-uniform seasoning, and contamination of dyes in conveying.

The introduction and use of the automatic distribution system makes the enterprise use a large number of workers and greatly improve the production efficiency.

The workshop control room is responsible for each dyeing tank scheduling, with only 3 managers.

1 of them monitor the production of each VAT in real time in front of the central control system interface.

In general, 1 dye vats are responsible for 1 dyeing batches. According to the technological time, the system will automatically remind and plan the dye vats in the next 8 hours.

The central control room required 6 managers to perform real-time monitoring for 24 hours, and 18 workers in the workshop were required to operate.

Now, using the central control system of dye vat to make the dyeing workshop intelligent, only 1/4 of the original work is needed, and the hit rate has increased by 5%. The daily dyeing batch has also increased from 2.5 to 3, and the production efficiency has increased by 20%.

This year

Chaozhou Shantou more than 200 printing and dyeing enterprises are faced with the trouble of concentrating on garden production. The process is painstaking and the Chaoshan dyeing and printing industry will usher in a new type of "Phoenix Nirvana".

During the "13th Five-Year" period, the primary task of the printing and dyeing industry is to form a digital monitoring system covering the whole process of printing and dyeing, and establish a digital printing and dyeing workshop.

On the basis of the development of on-line monitoring and control system for printing and dyeing process parameters, the latest technology is adopted to form a digital monitoring system covering the whole process of printing and dyeing. The system monitors the mechanical parameters, process parameters, energy consumption and process quality comprehensively, and integrates automatic dyeing and finishing system to form closed-loop control of the machine or unit.

In the new stage of development, it is urgent to develop the printing and dyeing equipment through the intellectualization of equipment to cope with the loss of population dividends and to promote green environmental protection in the production process.

Facing the entrance production, Chaoshan

We must take pformation and upgrading as the direction, improve quality and increase efficiency as the means, and rely on scientific and technological innovation and management innovation to enhance the operation capacity of the industry.