Transcript （冷堆）染色前处理 - Fountain Set (Holdings)

针织物平幅连续漂白系统（冷堆）染色前处理 、绳
状固色制软后处理设备介绍
Introduction of Dyeing-and-Finishing Machine
• Open-width Continuous Bleaching System
(Cooled Pad-Batch) for Knitted Fabric
• Pre-treatment in Dyeing Machine
• Post-treatment of Rope Color-fixing Softer
陈学平
Xueping Chan
江阴金田机械有限公司开发部
Jiangyin Jintian Machinery Ltd. - Development Dept.
福田实业（集团）有限公司全资附属机构
A wholly owned subsidiary of Fountain Set (Holdings) Ltd.
19.10. 2011
讲座简介Seminar Outline
• 集团简介
Group Profile
• 针织物平幅冷堆前处理设备介紹
Knitted Fabric Open-width Cold Heap Pre-process Equipment
• 绳状固色制软后处理设备介紹
Rope Color-fixing Softer Post-process Equipment
节能
Energy-saving
高效
智能化
High efficiency
Intelligence
集团简介 Group Profile
• 世界最大的圆筒针织布生产商之一
One of the world’s largest circular knitted fabric manufacturers
• 高度垂直综合服务包括：棉纱、染纱、缝纫线、针织布、染色、印花、整
理、生产及成衣销售、制造及销售纺织机械等
Highly vertical integrated operations  cotton yarn, dyed yarn, sewing
threads, knitted fabric, dyeing, printing, finishing, production and sale of
garments and textile machinery
• 向超过40个国家的成衣制造商提供布疋，以制成国际知名品牌的成衣
Major knitted fabric supplier to garment manufacturers in over 40
countries that supply to internationally renowned retail brands
集团简介 Group Profile
• 1969年于香港成立，1988年于香港联交所上市
Established in Hong Kong in 1969. Listed in the Stock Exchange of
Hong Kong Ltd. (SEHK) in 1988
• 2010财政年度之营业额超过 61亿港元
2010 fiscal year turnover: over HK$6.1 billion
• 全球聘用雇员超过15,600人
Globally staff force of over 15,600
- 香港 HK：3% - 中国 PCR：88% - 海外Overseas：9%
集团简介 Group Profile
• 总部设于香港，在中国、斯里兰卡及印度尼西亚设有生产设施
Headquartered in Hong Kong; production facilities in China, Sri
Lanka and Indonesia
• 海外市场推广办事处 / 代表处分布 5 个城市
Overseas marketing/ representative offices in 5 cities worldwide
• 对节能环保、清洁生产方面非常重视并加大了该方面的研发力度
Energy Conservation and Environmental Protection are our top
priority
江阴金田机械有限公司（簡稱「金田」）
About Jiangyin Jintian Machinery Ltd.
(“Jintian”)
公司介绍 Company Profile
• 近年研发出节能环保的新型染整设备，在多家附属公司的染厂广泛应用
Developed wide range of energy-savings and environmental protecting
equipments in dyeing and finishing, which are widely used in dyeing
subsidiaries
• 金田有多家大型染厂的技术支持和试验平台，研发的设备均能达到当今
节能环保的要求
With the technical support of many large-scale dyeing mills, our R&D
equipments are able to meet the strict energy conservation and
environmental protection requirements
冷堆前处理
Cold Heap Pre-process
冷堆前处理背景 Cold Heap Pre-process Background
冷堆技术在针织物方面应用的快速發展：
The significant development of cold heap technology in knitted fabrics:
• 近年国家对节能減排、清洁生产高度关注
Due to Nation’s high concern on energy conservation, emission
reduction in recent years
• 企业对降低成本有迫切需求，很多科研机构和企业也着重这方面的研发
Enterprises have urgent cost reduction need, which cause many
scientific research institutions and enterprises to develop it
冷堆工艺比较成熟，但真正应用到生产上还有许多技术难题要克服
Cold heap is a relatively mature technology, but when applying to
production, there are still many technical problems to overcome
针织物平幅冷堆前处理设备介绍
Knitted Fabric Open-width Cold Heap Pre-process Equipment
浸轧部分Padding
入布对中装置
Fabric
Centralizing
浸液槽
Liquid
Tank
轧车
Padder
布出折叠装置
Fabric Folding
加料桶
Refill
Barrels
过滤器
Filter
蒸洗部分 Steam Cleaning
入布对中装置
Fabric Centralizing
预热装置
Pre-heating
汽蒸装置
Steaming
轧车装置
Padder
洗水装置
Washing
对中装置
Centralizing
中和装置
Neutralizing
轧车装置
Padders
布出折叠装置
Fabric Folding
过滤器
Filter
加料桶
Refill
Barrels
针织物平幅冷堆工艺要求及5个阶段
5 Main Stages of Knitted Fabric Open-width Cold Heap Production
and its Requirements
阶段
Stages
时间Time
温度
Temperature
轧液率
Liquid
Rolling Rate
湿度
Humidity
pH值
pH
Value
1. 浸轧
Padding
8
(秒 sec)
-
120%-130%
-
-
2.堆置
Yarding
4
(小时 hrs)
25-30℃
-
65%
-
3.汽蒸
Steaming
10-15
(分种mins)
95℃
-
-
-
4.水洗
Washing
-
60-80℃
2洗2轧
Wash & roll
for 2 times
-
-
-
5.中和
Neutralizat
ion
-
常溫
Normal
temperature
-
-
6.5-7.0
工艺流程 Production Process
第一步 浸轧 Stage 1 Padding
浸
短时间內完成织物对
处理液的吸附与均匀扩散
To ensure the liquid are being
absorbed and spread evenly in
short time
第一步 浸轧(续) Stage 1 Padding (Cont’)
一半浸泡一半淋浴的好处：
The benefits of half-soaking and half-showering:
• 保证处理液的均匀
Ensure liquids are evenly spread
• 操作安全，料桶配有自动感应装置
Safe operation, barrels are equipped with automatic sensors
• 减少人手及成本
Save manpower and cost
浸液槽
Liquid
Tank
加料桶
Refill
Barrels
淋浴槽
Shower
Tank
第一步 浸轧(续) Stage 1 Padding (Cont’)
均匀轧车保障轧液率均匀
Padder ensures rolling liquid rate is even
采用特殊的设计去控制张力和卷边，确保织物的轧液率均匀
Adopt specially designed structure to control tension and roll edge
扩幅板装置
Extension Device
轧车
Padder
螺旋扩幅滾
Spiral
Extension Roll
第二步 堆置 Stage 2 Yarding
达到增溶、乳化、皂化、分解、氧化、溶胀
Concentration , Emulsion, Saponification, Decomposition, Oxidation, Swelling
处理液中的碱剂与表面活性剂、双氧水缓慢地与织物上的杂质、色素反应
The alkali and surface active agent of the liquid and hydrogen peroxide slowly react to
the impurities and pigment
将密封的布车堆放好
Place sealed fabric trolley in stacking area
排列堆放4小时
Piled up for 4 hours
第三步 汽蒸 Stage 3 Steaming
蒸
为快速催化的工序，加速双氧水的分解活性，令堆置时间大幅缩短，
提高生产效率
Steaming is a quick catalytic process -> accelerates decomposition
activity of the hydrogen peroxide, shorten yarding time and improves
production efficiency
织物在汽蒸的状态
Knitted Fabric
under Steaming
第三步 汽蒸 (续) Stage 3 Steaming (Cont’)
织物入蒸箱前配有预热装置，降低了织物在进入蒸箱的温差，避免织物瞬间
产生的温差影响织物品质
Preheating device reduces fabric’s temperature difference when enters
steam box and prevents adverse effect caused by temperature difference
在汽蒸的过程中有两道翻动织物的装置来保证汽蒸均匀
Two rolling knitted fabric devices to ensure steam are even
第四步 洗水 Stage 4 Washing
洗
是将已经分解、降解、乳化后的杂质通过连续的溢流清洗分散在水
中，并将织物身上的残留物全部洗净，达到半成品要求
Washing place decomposed, degraded and emulsification impurities in
continuous cleaning water. It washes residues away and meets the
semi-finished products requirements
第四步 洗水(续) Stage 4 Washing (Cont’)
• 通过先进的张力控制系统保障织物的张力
Advanced tension control system ensures elastic of fabrics
• 下有振荡打水滚筒，上有四道喷淋
Water roller for oscillation beneath and four sprinklers above
• 提高了水的利用率，降低了水的需求量
Improve water utilization ratio and save water
振荡打水滚筒
Oscillation
Water Roller
张力控制器
Tension Control
System
第五步 中和 Stage 5 Neutralization
通过均勻的补酸使布面pH值保持在6.5-7
Adding acid evenly to keep fabric’s pH value at 6.5 - 7
pH值探测仪
pH Value
Detector
操作智能化 Operation Intelligence
• 智能化触摸屏控制界面﹐方便操作
Intelligent touch screen computers are user-friendly
• 同步张力控制系统保证织物低张力运行﹐防止织物拉伸变形
Synchronized tension control system ensures fabric operates in low
tension process and prevents it stretches or deforms
操作智能化 Operation Intelligence
好处 Advantages：
• 减少人为因素造成的损失，降低人工
Reduces the loss caused by human factors and labour cost
• 可长期保存生产数据，如时间 、机速、温度、用水量、助剂用量等
Long-term preservation of production data, such as time, speed,
temperature, water consumption , additives dosage, etc.
工控电脑
Intelligentcomputer
PLC
变频器
Frequency
Converter
冷堆设备前处理与传统工艺前处理相比
Water, Electricity & Steam Saving Comparison between Pre-process of
Cold Heap and Traditional Pre-processing
50
45
40
35
30
25
20
15
10
5
0
传统工艺前处理
Traditional Preprocessing
冷堆前处理
Pre-process of
Cold Heap
耗水（L/kg）
耗电(kwh/T)
省水 Water Saving
14.2L/kg
省电 Electricity savings
22 kwh/t
省汽 Steam savings
0.98kg
耗汽（kg)
64.2%
节省
Saved
45.8%
69.5%
冷堆前处理与传统前处理效果对比
Comparison between Pre-process of Cold Heap and Traditional Preprocessing
对比项目
Contrast project
工艺处理
Production Process
传统前处理
Traditional Preprocessing
冷堆前处理
Pre-process of Cold Heap
温度 Temperature
95℃
25-30℃堆置 Yarding
95℃汽蒸 Steaming
加工方式
Processing method
绳状 Rope
平幅 Open-width
白度值
White degree value
/
接近 Similar
pH值 pH value
/
7-8
冷堆前处理与传统前处理效果对比
Comparison between Pre-process of Cold Heap and Traditional Preprocessing
对比项目
Contrast project
工艺处理
Production Process
传统前处理
Traditional Preprocessing
冷堆前处理
Pre-process of Cold Heap
吸水性
Hydroscopicity
-
接近 Similar
30杪以内 Within 30 sec.
毛效
Fur effection
-
接近 Similar
7-10cm/30min
成品规格
Finished product
specifications
-
接近 Similar
处理方式 Treatment
剧烈 Severe
缓和 Mild
冷堆前处理与传统前处理效果对比
Comparison between Pre-process of Cold Heap and Traditional Preprocessing
对比项目
Contrast project
工艺处理
Production Process
前处理布面效果
Pre-process cloth
cover effection
染色效果
Dyeing effect
传统前处理
Traditional Preprocessing
冷堆前处理
Pre-process of Cold Heap
摩擦较大
Large friction
毛羽多
rough surface
易产生褶皱
Easy to have fold
光洁、平整、手感较柔软
Smooth, flat and soft fabric
/
染敏感色如蓝绿色、啡色、灰色
等表现优异
Excellent performance in
dyeing sensitive colors
such as, turquoise, brown,
grey, etc.
技术成果 Technological Achievements
• 该技术从2008年开始研发，2009年正式投产
Started in 2008 and applied in production since 2009
• 目前已在国内多家大型染整企业广泛应用。并在业界获得一致好评及多
项国家专利
At present, it is widely used by many large-scale domestic dyeing
enterprises and has won consistent acknowledgements with multiple
national patents
绳状固色制软后处理设备介绍
Introduction of the Post-treatment of
Rope Color-fixing Softer Machine
绳状固色制软后处理设备
Post-treatment of Rope Color-fixing Softer Machine
• 为我公司最新研发的染色后处理设备
latest dyeing post-process equipment of Jintian
• 传统工艺中，固色、柔软工序需在染色机内处理，耗时长、能耗大，
不能满足节能环保的新需求，绳状固色机应运而生，节能等方面的优势在
我公司染厂赢得了一致好评
In traditional production, color stabilizing, softening process within the
dyeing machine is time and energy consuming. It fails to meet the new
trend of energy saving and environmental protection, thus rope
color-fixing softer machine is developed
• 该机通过6组轧辊、5组液槽、加料桶定量补充助剂、可在短时间内完成
固色、柔软工序
Can complete color stabilizing and softening process shortly with 6
groups of rolls, 5 groups of liquid tank and refillable additives
设备优势 Competitive Advantage
• 提高染色机的利用率，缩短了染色全过程的工艺时间，节约能源，
提高生产效率
Improve utilization rate of dyeing machine, shorten the time of dyeing
process, reduce energy consumption and enhance productivity
固色制软机与染色机相比
Water & Electricity Saving Comparison of Color-fixing Softer Machine
and Dyeing Machine
染色机
150
Dyeing
130
Machine
110
90
固色制软机
Color-fixing
Softer
Machine
70
50
30
10
-10
耗水（T）
省水 Water Saving
耗电(kwh）
65.1%
省电 Eelectricity Saving 45.0%
目标 Our Goals
我们将一如既往地开发染整行业的新型技
术，同时将这些技术和大家分享。为染整
行业的快速发展和环境保护的有效实施尽
自己的一份绵薄之力
We will continue to develop the latest technology of the
dyeing industry while adopting environmental friendly
practices throughout our operation
谢谢！
Thank you!