Transformation And Upgrading Of Imported Equipment To Achieve Low Pressure Washing Green Printing Of Knitted Fabrics.

With the continuous improvement of people's living standards, knitted products are more and more popular in the market. In recent years, the knitting industry has maintained rapid development. The printing process of knitted products at home and abroad mainly adopts intermittent processing such as rope drawing and cylinder drawing. There are many problems, such as large consumption of water and electricity, cumbersome technology, large loss of elasticity, and unstable fabric quality. With the increasingly stringent environmental requirements, these problems have become a major problem for printing and dyeing enterprises to survive and develop.

Located in the "famous underwear town of China", Shen Hu Town, Jinjiang, Fujian. Fujian Futian textile printing and Dyeing Technology Co., Ltd. union Xi'an Polytechnic University and Shaoxing Dongsheng Digital Technology Co., Ltd. After years of technical research, independent innovation has been developed. Key technology of continuous production of low tension and flat fabric for printed knitted fabrics It has realized the low tension washing process of printing knitted fabric and improved the washing quality of cotton and Nylon high elastic knitted fabric. Compared with the traditional cylinder washing process, the energy saving and emission reduction effect is remarkable. It is a major scientific and technological innovation in the textile printing and dyeing industry. It has an important exemplary role in the green production and processing of "high-quality, low emission" of knitted fabrics. "The key technology and equipment development of low tension, constant width continuous washing for printed knitted fabrics" was awarded the "textile light" 2018 China Textile Industry Federation first prize in science and technology. 。

Project Name: key technology and equipment development for low tension continuous flat washing of printed knitted fabric

The main completion units: Fujian Futian textile printing and Dyeing Technology Co., Ltd., Xi'an Polytechnic University, Shaoxing Dongsheng Digital Technology Co., Ltd.

The main participants are Chen Maozhe, He Jiangping, Shi Wen Zhao, Shang Yudong, Zhang Bohong, Lin Ying, Liu Jinshu, Tian Cheng, Tian Cheng, Hui, Hun, Hun, Hun, Hui, and

Innovative research and development, not superstitious foreign high-end equipment

Fujian Futian textile printing and Dyeing Technology Co., Ltd. is located in Shen Hu Town, one of the three major printing and dyeing centers in Quanzhou, Fujian. In recent years, with the strict implementation of the national environmental protection policy, the printing and dyeing enterprises in Jinjiang are facing a big problem of survival and death. Jinjiang has promulgated a series of policies for transformation and upgrading of the dyeing and finishing industry. Liu Wenru, Secretary of the Jinjiang Municipal Committee, clearly pointed out that the transformation and upgrading of the dyeing and finishing industry is imperative and imminent. Only by making efforts to upgrade the whole chain, upgrading the whole process, and taking the middle and high-end line, can we stimulate the strength of the dyeing and finishing industry and move towards the advanced manufacturing industry. To this end, Jinjiang issued the "Jinjiang city to accelerate the transformation and upgrading of printing and dyeing industry action plan", put forward the "good quality, clean up, cluster integration, control quantity upgrading, energy saving and emission reduction" overall guidance.

Fujian Futian textile printing and Dyeing Technology Co., Ltd., in response to the call of the government, is committed to transformation and upgrading, and has introduced many high-end equipment from abroad. Continuous water washing after textile printing is the embodiment of high efficiency and energy saving. At present, the washing processes of knitted products at home and abroad are mainly rope washing, rope washing and continuous washing.

Rope type cylinder washing is a traditional intermittent rough processing method. It is suitable for all kinds of knitted fabrics. Every process is repeated water injection, drainage and many times downtime. The consumption of water and electricity is large, and the fabric is wrinkled. The surface of some fabrics will appear fuzz, fuzz and damage. At the same time, multi cylinder washing can easily cause problems such as cylinder difference, strip difference and inconsistency between the color of the cloth surface and so on, which seriously affects the quality of products. Rope continuous washing is only suitable for washing of polyester products.

Although flat width continuous washing can solve the above problems of traditional rope washing and rope continuous washing to a certain extent, there are many problems such as excessive tension, floral deformation and fabric loss.

In view of the problems existing in the washing of the knitted fabric after printing, the company introduced the high le continuous width washing machine and applied to the printing and washing process of knitted fabrics. However, according to the actual production feedback, because the imported equipment is mainly designed for the European production environment, it is difficult to match the fabric quality, matching washing AIDS, the setting of process parameters, and the operation parameterization of the equipment from the domestic market. It is difficult to match with the fabrics, auxiliaries and processes used in the production and processing of domestic enterprises. Therefore, there are still many problems such as the high cost of industrial production, too much investment in equipment, immature technology, unstable quality of processing fabrics, and limited application (color, color fastness and other quality indicators). Moreover, enterprises are also in urgent need of water-saving, energy saving, emission reduction, quality control and stable printing technology applied to production practice.

Futian company plans to carry out the new upgrading and upgrading of imported equipment on the basis of digestion. An accidental opportunity to let the company get to know the professor of Xi'an Polytechnic University, the two sides chime in with each other, decided to carry out industry university research cooperation, set up project research and development team to solve the above problems.

According to the technical personnel of the company, through many years of key technical research, the project has independently developed innovative printing technology and equipment for low tension, constant amplitude and continuous washing. The main technical contents include: automatic control system of over feeding tension to reduce fabric tension, vibrating net water washing cloth roller, slit vacuum suction device, spray water washing unit, new type fixing agent, developing a whole set of washing process, configuring waste water circulation purification treatment system, realizing automatic wastewater recycling treatment and reuse.

Achieve energy saving, emission reduction and cost reduction.

At present, the key technology of the project has been well applied in Fujian Futian textile printing and Dyeing Technology Co., Ltd. On the basis of the key technology and equipment research and development, 2 printing and washing continuous production lines of printed knitted fabric have been built and put into operation for many years. The continuous washing process of the knitted fabric after printing has been realized, and the washing quality of the cotton and Nylon high elastic knitted fabrics has been improved. The color fastness, stretch elasticity and other performance indicators meet the requirements of relevant standards, and the quality of cloth surface is obviously better than that of traditional process products.

According to the introduction, the technology runs through all aspects of printing, knitted fabric pretreatment, printing, washing, post-processing, finished products and sales. The water saving rate can reach over 50%, and the standard coal can be saved over 1500 tons in 3 years. The waste water can be reduced by more than 1 million 500 thousand tons in 3 years, and the waste water treatment cost can be saved more than 5 million yuan.

For Fukuda, the application of the key technology and equipment development of low tension, constant width and continuous washing of printed knitted fabrics can significantly reduce the production cost and maximize profits; for consumers, products are more in line with the quality needs of consumers; for the industry, the project has developed the key technology and equipment of low tension, flat and continuous washing of printing knitted fabrics with independent intellectual property rights, which has realized the key technology of green dyeing and finishing technology in the key areas of textile industry development planning (2016~2020 years), namely, the breakthrough of flat processing technology of knitted fabrics, promoted the technological innovation and product innovation of the textile dyeing and printing enterprises, and promoted the new competitive advantage of the industry.

"The success of the project laid a foundation not only for Futian's own transformation and upgrading, but also for the green development of the dyeing and finishing industry." During the interview, the company official told reporters.