China'S Famous Blended Yarn City: New Pattern Of Technological "Weaving" Production

Youxi, the "Pearl of Central Fujian", is known as "China's famous leather fabric city", "China's famous blended yarn city", "provincial textile foreign trade transformation and upgrading base", etc. The textile industry is the first pillar industry here, and the textile industry chain is also the first 10 billion featured industry chain in the county.

In recent years, the textile industry of Youxi has been developing in the direction of digital transformation, quality improvement and innovation, and has initially formed the characteristic leather base fabric industry chain of "spinning weaving dyeing finishing coating (leather making)". At the same time, it is making every effort to build the industry chain of "nylon filament weaving (warp and weft knitting, flower knitting) dyeing finishing clothing". According to the data, there will be 96 textile enterprises in Youxi County in 2024, including 57 textile enterprises above designated size, with an output value of more than 10 billion yuan. Last year, the production capacity of Youxi printed and dyed leather substrate reached 170 million meters and 50000 tons of knitted fabrics; The spinning production capacity has exceeded 1.5 million spindles; The production capacity of nylon filament exceeded 135000 tons, ranking fifth in China.

Vertical integration

"One piece of silk" becomes "one piece of clothing"

How many enterprises and workshops need division of labor and cooperation from "one silk" to "one garment"? The answer given by Fujian Liurong Industry Co., Ltd. is only one production line.

On April 8, in the ready to wear incubator workshop of Fujian Liurong Industry Co., Ltd., located in the Chengnan Industrial Concentration Zone of Youxi County Economic Development Zone, 10 full-automatic hanging lines were full of clothing pieces, and the employees completed the sewing by relay and finally made ready to wear. Sunscreen clothes, yoga clothes, outdoor quick drying clothes and pants... One by one high-quality clothing has been manufactured and ready to be sold all over the world.

"Our vertically integrated intelligent factory is the first attempt of global knitting chemical fiber projects, which can achieve continuous production from nylon spinning to fashionable sports clothing in a single factory." Chen Jingwei, president of Liurong Industry, told reporters that the integrated production mode can not only save production cycle, but also provide customized services for customers.

The so-called "vertical integration" refers to the closed-loop production of the six industrial chains of spinning, texturing, weaving, dyeing and finishing, printing, and garment in a single factory. The ready to wear incubator workshop of Liurong Industry will be completed and put into operation in September 2023, covering an area of 10000 square meters, with an annual output of 4 million pieces of standard ready to wear. At present, it has carried out in-depth cooperation with many first-line brand customers at home and abroad.

"The incubator is not only built for production, but also plays an important role in cultivating talents in advance." Chen Jingwei told reporters that garment workers need a relatively long training period. They can recruit workers, produce and train at the same time, so they can train mature workers for the first phase of the project under construction, and develop a sound production process, So that the Phase I project can be put into production immediately after completion.

At present, the first phase of the fabric plate project of Liurong Industry is stepping up construction. It is expected to be completed and put into production in the third quarter of this year, which can achieve an annual production of more than 15 million pieces of clothing. "After the completion of Phase II and Phase III projects, the annual output of 35000 tons of nylon fiber, 15000 tons of high-grade printed fabric, 60 million swimsuits, 40 million sportswear and golf jerseys can be achieved, with an annual output value of more than 5 billion yuan," Chen Jingwei said.

Digitization of production

Weaving becomes "intelligent"

As a traditional labor-intensive industry, the lively scene of "thousand people yarn, ten thousand people cloth" was once a true portrayal of the textile industry. In Fujian Xinsen Synthetic Fiber Technology Co., Ltd., the reporter saw a different picture.

There are only a few workers in the nearly 20000 square meter texturing workshop. Rows of automation equipment are running at high speed. On a 100 inch smart screen in the workshop, all kinds of data on the production site are constantly beating.

"This smart big screen can record real-time data such as location distribution and operation status of spinning equipment, help operation and maintenance management personnel quickly master the basic situation of the production line, and timely find unexpected problems." Tan Yankun, vice president of Xinsen Synthetic Fiber, told reporters that in June last year, Xinsen Synthetic Fiber and China Unicom Fujian Branch jointly created "5G" The project of "Smart Factory" was included in the list of 5G factories in 2024 of the Ministry of Elections, Industry and Information Technology.

"Previously, although the workshop had a high level of automation, the production process was still a single machine data operation, resulting in problems such as low overall management efficiency, lack of process management, and difficulty in statistics of production quality, management, efficiency and other data." Tan Yankun told reporters that the application of "5G smart factory" completed the digital and intelligent transformation of the workshop. At present, orders, production, equipment, management and other aspects have been digitized, production management and operation efficiency have been effectively improved, and cost reduction and efficiency increase have been achieved.

The application of digitalization provides technical support for enterprise product upgrading. Last September, the product of "porous super fine denier nylon elastic yarn" independently developed by Xinsen Synthetic Fiber won the title of single champion product in Fujian manufacturing industry.

Porous super fine denier nylon elastic filament is thinner, lighter and softer than ordinary nylon civil filament, with the characteristics of light, thin, breathable, high flexibility and high water absorption. However, in the traditional manufacturing process, this material is prone to problems such as broken ends, wool, uneven network, poor fiber cohesion, uneven dyeing, etc. Now, in the "5G Smart Factory", CNC equipment can solve these problems through remote and fully automatic control of screw pressure, temperature and humidity, side blowing cooling, oiling and bunching, false twisting and drafting and other processes.

"At the same time, the '5G Smart Factory' can also add nano silver ions through the coating dust technology, or manufacture antibacterial fibers and mosquito repellent fibers through the supercritical extraction mosquito repellent plant technology, according to the market demand, which has a strong inhibitory and killing effect on bacteria, fungi, trichomonas, gonococci, chlamydia trachomatis and other pathogenic microorganisms." Tan Yankun said.

The reporter learned from the Bureau of Industry and Information Technology of Youxi County that in recent years, Youxi County has focused on the digital transformation and innovation leadership of the textile industry. Last year, a total of six national high-tech enterprises, five provincial-level specialized new enterprises, one provincial-level single champion enterprise, and seven technology-based SMEs were cultivated.

Green development

Waste plastic becomes fashionable fashion

In Youxi, an abandoned plastic bottle can also be transformed into clothing materials through transformation.

On the morning of the 9th, when the reporter came to Fujian Youxi Huayang Fiber Textile Technology Co., Ltd., he saw that the neatly stacked plastic bottles were cleaned, sorted, screened and broken into PET bottle pieces, and then dried, melted, and brushed, and the recycled environment-friendly polyester staple fiber was generated.

"There are many textile enterprises that use waste plastic bottles as raw materials for production, but we are the first enterprise in China to complete the whole chain production of 'waste recycling - regenerated fiber - yarn'." Zheng Zunrong, chairman of Huayang Fiber Textile, told the reporter that not only that, but also the company's expenditure on sewage treatment accounted for one fifth of the total investment.

In addition to Huayang Fiber Textile, many textile enterprises in Youxi are striving for green development.

Fujian Dongfang Xinwei Textile Technology Co., Ltd. has been constantly exploring and optimizing the process flow in the production process, adopting new spinning technology, reducing energy consumption in the production process, and reducing noise pollution. The vertical integrated production of Liurong Industry has greatly reduced the packaging loss, transportation cost and energy consumption of the balance workshop. "The nylon filament needs to stand for 48 to 72 hours before leaving the factory. After traditional transportation, it needs the same time for two times of standing. Now integrated production can save repeated links, promote the reduction of workshop area and air conditioning energy consumption." Chen Jingwei said.

Ruan Renyu, secretary of the Party Working Committee of Youxi County Economic Development Zone, said that the textile industry in Youxi actively responded to the call of the state for green development, encouraged enterprises to "leave the city and enter the park" through various preferential policies, promoted industrial agglomeration, introduced the most polluted dyeing and finishing links in the textile process into the industrial concentration area in the south of the city, and established a unified sewage discharge area, Furui Thermal Power in the park will supply gas and heat uniformly, making the whole industrial chain more energy-saving, environmentally friendly and safe.

"At present, we are gradually introducing photovoltaic projects, using plant roof resources to increase the proportion of clean energy, reduce dependence on traditional fossil energy, and realize the green transformation of energy supply," said Ruan Renyu.

By the beginning of 2025, 4 of the 13 enterprises above the designated size in the park have won the title of green factory, including 3 national green factories and 4 provincial green factories (including national green factories). "It is estimated that by 2027, we can cultivate more than five provincial green factories, strive to reach the national green factory standard for three of them, and promote enterprises in the park to further achieve energy conservation, emission reduction and resource recycling." Ruan Renyu said.

(Source: Zhuang Ziyi, trainee reporter of Fujian Daily, Wang Kunwen, correspondent)