Liaoning Tianwei Textile Research Architecture Design Co., Ltd. (Textile Industry Nonwovens Technology Development Center)
With the rapid development of China's economy, the nonwovens industry has continued to develop at a relatively high speed. Until recently, its average annual growth rate has reached double digits, and the annual production has exceeded 1.6 million tons. The rapid development of the economy has driven the rapid growth of the consumer market, and the demand for various types of nonwoven products is also growing. From 2006 to 2008, the production of non-woven fabrics in China increased by about 200,000 tons, indicating that non-woven fabrics still have good development prospects.
In the rapid development of China's nonwovens industry, we should also see problems arising from development. These problems restrict the healthy development of the industry and the economic benefits of enterprises to varying degrees. Therefore, it is necessary to explore existing problems in the industry and Take corresponding countermeasures to promote the development of the industry to a higher level.
1 Analysis of existing problems
1.1 Capacity Expansion In recent years, the repeated expansion of the production capacity of similar products of various types of nonwovens has led to increased competition in the traditional market for large road products, which has led to a decline in profits of some enterprises. The original capacity expansion leads to market competition as an inevitable result of objective law, and it will be more favorable to consumers through competition. It is also conducive to promoting the advancement of technology and management in enterprises, but some bad viciousness The phenomenon of competition has a negative impact on the orderliness of the industry.
1.2 Enterprise size problem
In the mid-1980s, China began to form a scale of non-woven fabric production, which has gone through more than 20 years of development. In the early stage of development, China's non-woven fabric industry has the characteristics of large enterprises, small scale and poor capacity. The average scale of enterprises has been greatly improved since the development, but there are still many phenomena and relatively small scale. For example, according to the statistics of China Industrial Textiles Industry Association in 2007, the average production capacity of spunlace enterprises is only about 2,500 t/a; the average production capacity of spunbonding enterprises is 4,500 t/a, and the single-line production capacity of new spunbond production lines has increased in recent years. Mostly it is only about 1500 t/a. Enterprises have increased with the increase of equipment, and the industry still has the basic characteristics of the initial enterprise structure, which makes it difficult to have good benefits in the face of low-margin conventional product markets, and is not conducive to gaining competitive advantage.
1.3 Product grade problems China's non-woven fabrics have been developed to date, and their product types, quality and grades have been significantly improved. The grades of export products are also increasing year by year, but compared with the world's advanced level, there is still a big gap. According to the situation from the industry and the analysis of customs import and export statistics in 2008, the gap is mainly reflected in: 1 products are mainly concentrated in the existing road products, and high-tech products are insufficient; 2 the overall product quality is not high enough, and some product quality can not be To meet the requirements of specific markets; 3 there is still a big gap between product development capabilities and variety types, and it is not able to provide many products that are currently needed in the international market. Some special domestic needs are still dependent on imports. The above situation shows that China's product grades are still at the middle and low level.
1.4 Equipment Improvement Issues China's non-woven equipment has also made significant progress with the rapid development of the nonwovens industry, high-speed carding machines, wide-format high-speed needle punching machines, and wide-spun spunbonds, various types of spunlace, hot rolling and other equipment. Both have been developed and widely used in production. Recently, PP/PE two-component spunbonding method, PET fine-denier spun hot rolling method and SMS composite production line have been successfully developed. The two-component spunbonded spunlace production line has also begun. Developed. Strictly speaking, there is still a big gap between China's equipment manufacturing level and international level, mainly in processing precision, equipment stability, suitable processing materials, network quality, production speed, automation and after-sales service. The main reason for these problems is that some equipment manufacturers have backward machining methods, lack of understanding of process and production practices, lack of controllable software technology and disorderly competition in equipment manufacturing.
1.5 Market development problems At present, China's non-woven fabrics have been applied to various fields such as industry, clothing and decoration. Not only have the market been expanded, but also some new markets have been developed. However, the vast majority of China's non-woven fabric production capacity is concentrated in a few traditional large-distance goods market, and the accumulation of capabilities has caused oversupply in some markets and reduced profits. However, there are many markets that are far from being developed or not yet developed, such as agriculture, protective clothing, medical, and construction engineering. Some of the urgently needed products developed often fail to meet international standards. The low-end of the market and products, the lack of core competitiveness of enterprises and the lack of technological development capabilities have all constrained the scientific and technological progress and high-level development of China's non-woven fabric industry, and also hindered China's high-tech non-woven products. Quickly enter the international market.
1.6 Brand Creation Problem The brand effect can make a company's sales performance far better than its competitors. Establishing your own brand is especially important for group companies and multinational companies involved in the international market. Brands can be replicated repeatedly with the expansion of the company, and the brand effect will be expanded indefinitely. Most brands are not created by a single company, but by a group of companies. Due to the small scale of China's enterprises, there are not many group companies with true international competitiveness, and the products are mainly positioned in middle and low-end products (including export products). There are few high-end products with international influence. Brands are created, so there are still very few companies in China's nonwovens industry that currently create brands. An industry lacking a brand can also be said to be an industry that lacks vitality and development. Therefore, attaching importance to brand building is a very important task for enterprises.
1.7 Standard setting issues The standard setting of nonwovens includes relevant construction, design, product testing, performance indicators, etc. in the industry, as well as national regulations and standards for the application of new materials. The former is conducive to standardizing production and ensuring product quality, promoting the standardization of the industry, while the latter can promote the rapid promotion and application of new products and new materials. In the past 10 years of development of non-woven fabrics in China, some related standards have been formulated one after another, but the speed is slow and the categories are incomplete. The early standards and regulations have not been revised in time, which is far from satisfying the development. Need, even severely restrict the development of nonwovens.
2 Countermeasures to promote the development of the industry The above-mentioned problems restrict or hinder the rapid improvement of the technology and the overall healthy development of the Chinese non-woven fabric industry. Therefore, it is necessary to further discuss these issues from the perspective of the overall industry. And take corresponding countermeasures to gradually overcome the unfavorable factors and promote the all-round development of China's non-woven fabrics.
2.1 Increasing market development while expanding capacity The market is expanding to promote the expansion of non-woven fabric production capacity, and the expansion of production capacity to several established markets will lead to increased supply and demand. Therefore, we must avoid or reduce the pressure of competition. On the one hand, we should avoid low-level redundant construction of similar products, continuously improve the technical level of production equipment, and improve product quality and production scale. On the other hand, we must increase the development of the market to make production. The ability to spread to more areas. China's non-woven fabric industry should also strengthen the guidance of the enterprise market positioning and division of labor awareness, so that it can clearly define its own market positioning, and let the market gradually enter the track of benign competition and standardization.
2.2 The development of the enterprise has gradually turned to grouping and large-scale. Although China's non-woven fabric production capacity and actual production have entered the world's top two, but the international competitiveness is relatively low, this is related to China's non-woven fabric enterprises. A small, loose, multi-scale structure is not unrelated. Although there have been some strong group-oriented enterprises in China in the past 10 years, there are not many group companies with international competitiveness in the true sense, and fewer companies that can brand in the international market. Today, with the integration of the global economy and the gradual internationalization of the domestic market, such a corporate structure is difficult to win a competitive advantage. Therefore, China's non-woven fabric industry should guide and help enterprises, through the cooperation, integration, mergers and reorganizations between enterprises or upstream and downstream, gradually embark on a group road, forming a batch of production scale, research and development capabilities, core competition The company's corporate group, in order to enhance its competitiveness in the domestic and foreign markets.
2.3 Strengthening cooperation and rapidly improving equipment level To improve China's equipment level, each equipment manufacturer needs to do several tasks: 1 adhere to the basic principles of excellence in equipment manufacturing; 2 pay attention to the detailed study and discussion of equipment structure and process selection, and Work closely with experienced production and practice personnel; 3 absorb and digest foreign advanced technology, and pay attention to mastering software and hardware work; 4 update equipment, apply advanced and precise processing equipment, improve manufacturing processing precision; 5 strengthen mutual cooperation between enterprises Strong combination, long and short, like Spinnbau and Dilo (Germany), Thibeau and Asse-lin (France), to develop a perfect complete non-woven production line with or close to the international advanced level. At the same time, we should not neglect the standardization of the competitive environment of the equipment manufacturing industry, eliminate the disorderly competition and the resulting cut corners, and the poor phenomenon of inferior filling, creating a good environment and conditions for the rapid improvement of the level of non-woven equipment.
2.4 Emphasis on the improvement of product grades and the creation of brand products is not a product, but covers a combination of product quality, production stability, variety serialization, functionality and innovation. China's non-woven fabrics have a low grade, in addition to quality and stability issues, especially in the development of functional and variety serialization. In order to improve the grade of products, we must pay attention to the use of new technology equipment or effective transformation of the original equipment, to improve the management level of the enterprise and the operational skills of the operators, and to strengthen the research and development to continue to develop new products.
After upgrading the product grade, we should also strive to create our own brand, which is also one of the purposes of the company to take the road of grouping. Because only groupization is easier to create a brand, and its brand plays a greater role under the advantages of strong financial support and overall system support, and then use the brand effect to achieve its own competitive advantage. It is worth mentioning that whether developing new products or creating brands, we should not neglect the idea of ​​establishing value innovation, the purpose of which is to create greater value for customers. Only when this basic condition is met can the developed results be easily copied and the long-term competitiveness of the enterprise can be formed.
2.5 Promoting standardization that is conducive to the development of the industry The formulation of standards for non-woven fabrics and related applications in China is still very imperfect. Many of the many processes and products have not yet been formulated, and the state lacks regulations and application specifications for mandatory use of new materials. . It is recommended to accelerate the formulation of relevant standards in the industry and make recommendations to relevant national departments to promote the improvement of regulations or norms for the application and application of new materials in the application field, and promote the formation of industry standardization.
3 Conclusion The nonwovens industry is an emerging industry that develops itself and has the development advantages that traditional industries do not have. However, there are also more prominent constraints than traditional industries. Therefore, it is necessary to explore the existing problems in the industry and find solutions to problems that are not conducive to the development of the industry. It is recommended that industry associations organize enterprises to seriously explore industry issues and their countermeasures, and gradually lead the industry to a more standardized and more conducive to healthy development, to achieve a rapid upgrade to the higher level of the nonwovens industry.
Liaoning Tianwei Textile Research and Architectural Design Co., Ltd. in June 2009 Liaoning Tianwei Textile Research and Architectural Design Co., Ltd. (formerly the textile industry non-woven fabric technology development center) is a national-level research and development of non-woven fabric technology and equipment design. The professional unit of manufacturing, production line installation and commissioning and plant planning and design has double grade A design qualification (class A of construction engineering, grade A of textile industry) and passed ISO 9001:2000 international quality management system certification. Now we have designed and manufactured more than 60 sets of polypropylene/polyester spunbonded nonwovens production lines for domestic and foreign customers, and exported them to Syria, India and other countries, becoming the world's three major spunbonded nonwovens equipment manufacturers and engineering contractors. One of the businesses.
Liaoning Tianwei Textile Research Architecture Design Co., Ltd. purchased the polypropylene from Japan's Kobe Steel Company in 2006. It can also be used in the manufacturing technology of polyester production. The equipment has its unique advancement and the following characteristics:
1. The production line uses a flexible design, the same production line can produce different raw materials, that is, the ability to process a variety of polymers: such as PP, PET. The product can reach a fine denier level: PP can reach 0.5 denier and PET can reach 1.5 to 2 denier. It can produce high quality thin polyester spunbonded hot rolled non-woven fabrics with a weight of 30g/m2--240g/m2, good product uniformity, high strength and soft handfeel. The box is a spinning box specially designed for the production of spunbonded nonwovens, with a wide enough spun beam and 8 built-in spinning pumps. It can produce 3.2 meters wide non-woven fabric. The structure of the spinning box has the characteristics of good integrity, excellent thermal insulation performance, uniform melt distribution, uniform temperature, short residence time, small pressure drop and no dead angle. The best conditions are achieved for the ideal heat transfer of the spinning assembly and for the full and uniform heating of the melt.
2. The cooling zone is short. There is a spin-wire quenching device that is capable of freely changing the operating state and the two faces are at atmospheric pressure. The distance from the spinneret to the drafting device is within 2 meters, and the distance between the drafting device to the spinneret and the drafting device to the screen curtain can be adjusted according to different raw materials and different process requirements, that is, the equipment drafting device The up and down position can be changed, which is the key to spinning a variety of raw materials on the same equipment. The advantage is that the drafting point can be moved up, the melt temperature is increased during spinning, and the drafting force is reduced, which is favorable for obtaining sufficient drafting, so that a finer denier and a relatively high relative strength can be obtained.
3. Integrated drafter and spinneret technology. The device has a positive pressure integral drafter of sufficient width, the drafting tube becomes a slit with the same width as the machine, and enters a high-speed airflow (positive pressure) from the side at the inlet of the yarn, which can change the filament arbitrarily Direction and spin speed. When the stretching speed is high, the energy consumption is not too large. It can achieve very low fineness and small residual stretch, while the uniformity of the laid net is much better than that of the tube, and the drafting is basically similar.
The integrated drafter air drafting technology has unique characteristics. It adopts the patented Kobe steelmaking technology with independent intellectual property rights. The speed in the drafting chamber is supersonic, and the working energy is strong and the efficiency is high. The air flow is drawn in one step, and the wire speed is greater than 5000 m/min. The airflow is used instead of the viscous friction between the airflows, the drafting efficiency is high, the structure of the equipment is relatively simple and easy to control, and it can adapt to various processes and varieties, and the fiber formation is relatively uniform.
In view of the low lateral tension of the single slit fabric, the specially modified overall drafter has a double slit. This technology is leading the world's latest level and is the current direction of airflow stretching equipment reform.
4. High-speed spinning range: PET 5000～5500 m/min, PP 4000～4500 m/min. Due to the short spinning process, the air resistance is small, the inertial force is large, and the spinning speed can be increased. Therefore, a higher degree of fiber orientation and crystallinity can be obtained, and not only the relative strength of the monofilament is high, but also the adhesion between the fibers, the filaments, and the like are less likely to occur.
5. High-speed fiber mesh production speeds of up to 250 m / min. The pendulum is divided by the speed difference between the spinning speed and the screen. When the speed difference is large, the wire will be automatically swayed from front to back, left and right, and the greater the speed difference, the better the uniformity of the pendulum. Due to the high spinning speed of this technology, a nonwoven fabric having good uniformity can be obtained.
The negative pressure under the screen of the net screen not only undertakes the task of air drafting, but also ensures smooth laying of the net, ensuring that no overturning occurs. The drafting is not closely connected with the screen of the net, and the outside air has entered, and the negative pressure under the net Mainly to keep the paving stable.
6. Select oil to heat the thermal bond.
7. The product has excellent uniformity.
Due to the above characteristics, the fabric produced by the process has high strength, good uniformity, soft fiber, good shape, and good shielding effect, and the water pressure resistance can be no less than the SMS cloth.
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