The application of high and new technology in the pulping workshop

I. Introduction

The printing and dyeing industry is a key industry for textile deep processing, finishing and value-added, and is a comprehensive reflection of the development and technical level of the textile industry. With the new technology of textile printing and dyeing and the continuous development of new technologies, textile printing and dyeing equipment is also constantly updated. At present, new equipment for pre-treatment, dyeing, printing and finishing in the printing and dyeing industry has emerged in an endless stream. In particular, the IT industry has gradually entered the textile printing and dyeing industry. The new CAD/CAM technology for printing and dyeing has brought a new revolution to the printing and dyeing industry. However, the printing and dyeing process is still in the manual operation stage, which has become a bottleneck that hinders the improvement and development of printing and dyeing technology.

As China enters the WTO, textile exports will continue to increase, and international competition will become more intense, so the quality requirements will be more stringent. At the same time, the requirements for eco-environment in the world make clean production, green consumption increasingly become the mainstream of development. In the traditional printing and dyeing process, the mixing and matching color is manually completed, the precision is low, the accuracy is poor, the human factor has great influence, the labor intensity is high, the operating environment is bad, the sample has poor guidance to large production, and the technical files and materials are completely artificial. Experience accumulation and manual recording, computer information management of technical files cannot be realized, and online call and check of technical data cannot be completed. Therefore, in the production, color inaccuracies or inconsistencies are often not met, resulting in the need for repairs to be shipped, not only failing to deliver on time, but also wasting manpower and material resources. At present, export products often require left-right color difference, the standard of color difference within the batch is above 4.5, and the order must reach the order of level 4. The color light source is also developed from the original natural light, the office ordinary fluorescent lamp to D65, CWF, TL84. , U30 and other standard light source color, and by a light source to increase the color to two light sources, and even require a variety of light sources do not change color, etc. is far higher than the national standards; on the other hand, due to the current color printing test in the printing and dyeing industry The sample still uses the traditional method of first sampling according to the customer's sample, and then zooming in on the machine. The technicians who use the sample proofing and the coloring in the production have to train for a long time to be competent in the dithering work, so the degree is large. It also relies on experienced technicians. As the flow of talents becomes more frequent, the company's products will be unstable.

In order to reduce dithering, the dependence of color on people, reduce the number of samples, and improve the level of the sample. Reduce the inter-batch chromatic aberration and the chromatic aberration in the batch due to the error in the weighing process in the production process. After repeated argumentation and absorption of the advanced experience of foreign printing and dyeing enterprises, Nantong Textile Dyeing Group Co., Ltd. introduced the printing and dyeing developed by Hangzhou Open Source Computer Technology Co., Ltd. Fully automatic computerized mixing and dosing system. Since May 2006, production applications have been gradually accepted by workshop production. The number of samples during dithering is greatly reduced, and the color difference control is significantly improved. The system not only achieves automation of mixing and color matching, but also accurately weighs materials, and integrates functional modules such as cost analysis into this system, so that enterprises will get more in terms of cost reduction, management level and product quality. More economic benefits.

Second, the introduction of automatic printing and mixing system

1, the components

The open source printing dyeing and dyeing system consists of ALICK (Alice) pulp mixer, paste machine and ANCOLOR software.

The ALICK pulper uses a product data management system and a high-precision electronic scale. It has an independently operable production system and proofing system to ensure consistency between proofing and production. It has a computer storage recipe function for returning and adding orders. The accuracy of the color provides a guarantee. The system has 50 maximum available mother colors and is fully computer controlled. The maximum amount of sample mixing is 30kg (with 34kg electronic scale), and the maximum amount of pulp for production is 100kg (with 150kg electronic scale). The system is equipped with a fully automatic mixer and automatic conveyor belt, which saves the use of labor and can greatly reduce the consumption of the largest consumables in the whole process. It not only improves production efficiency, but also minimizes the processing cost during the printing and dyeing process.

The ALICK Paste Machine is a system for the preparation of printed pastes. It is not only an independent original paste preparation system, but also can be connected with the fully automatic computer pulping system to complete the overall automation configuration of the printing and mixing workshop. The system is a high-tech product integrating mechanical, electronic, precision weighing, database management and network technology. The computer management system can be independently operated, and the viscosity of the prepared original paste is automatically controlled and adjusted, and the gouache is uniformly mixed, and the adjusted slurry is used immediately. It ensures the freshness of the printing paste, the fineness of the paste, saves the dye and improves the production efficiency.

ANCOLOR software is a comprehensive computer management of the production process, formulation and distribution of printing and dyeing products. According to the process formula and order color requirements, the process and formula are quickly formulated by calling the system data, which greatly improves the sample rate of proofing and production, reduces the proofing time, and ensures the production quality.

2. Development of pulping system

The starting point for the development of this system is: With the continuous improvement of product quality requirements in the printing and dyeing industry, the production process must inevitably consider a high starting point and adopt high-tech, high-efficiency system solutions. For printing/dyeing/dispensing/dispensing, the key is to ensure the accuracy of the printing dyeing process formula, to ensure the reproducibility of the process formula, to reduce the waste of the process of mixing and dispensing, and to better produce the printing dyeing machine. Efficiency, in order to achieve the purpose of improving product quality.

3. Computer pulping system process

The production department computer enters the order information through the open source Mansailong database management software, and the information is stored in the server database; the process room is experimentally developed to formulate the sample recipe and make a sample, establish a computer process recipe library, and pass the color matching software when using The color measured by the color matching instrument (such as spectrophotometer) is removed and restored to the database, and the similar color is found in the formula library, and the closest recipe data is found, and the new one is directly used or modified slightly. Formula and continue to enrich the recipe library. The computer pulping system and the paste preparation system automatically calculate, modulate, and distribute the pilot and large-production slurry through the control of the Mansailong launching operation software.

4. Main features of the pulping system

(1) Accurate color reproducibility and automatic color change function

The system is equipped with high-precision imported electronic scales. The pilot and production dyeing materials are taken from the same storage tank. The system realizes functions such as automatic weighing and automatic color change to ensure the accuracy of the slurry formulation and the reproducibility of color light.

(2) Using imported pneumatic diaphragm pump, fast and efficient

The imported pneumatic diaphragm pump is used to quickly and efficiently pump the mother liquid and keep the mother liquid flowing in one direction. At the same time, the mother liquid flow is separated from the internal structure of the pump through the diaphragm in the pump to ensure that the mother liquid does not contact the internal structure of the pump, and the lengthening is extended. Pump life.

(3) Using high-quality imported raw materials to make mother liquor storage tanks with strong corrosion resistance

The mother liquor storage tank is made of imported raw materials, and the service life is long. At the same time, large-tank storage is used for the commonly used dyes to improve the use efficiency.

(4) High mesh filter to ensure that the mother liquor contains no impurities

The system sets an in-line filter in the mother liquor distribution and circulation process. The filter adopts a high mesh stainless steel filter screen according to the needs of the printing dyeing process, and removes the particulate impurities that do not meet the requirements of the production process, thereby ensuring the purity of the mother liquor and greatly reducing The color point phenomenon, the filter core is easy to assemble and disassemble and clean.

(5) Specially designed mixing system features

A lifting device is designed for automatically lifting and stirring the slurry, so that the slurry is stirred up and down uniformly. The automatic cleaning device enables the mixing paddle to be fully automatic, reducing the pollution of the working site and creating a good working environment.

(6) mother liquid feeding and feeding device

The mother liquor adopts semi-automatic weighing and discharging system, which connects the electronic scale with the control computer to ensure the weighing accuracy of the powder and record the weighing data in real time. The chemical and water are accurately metered by the flowmeter to ensure the mixing ratio of the gouache, and the automatic feeding after mixing The device and pipeline are transported to the respective mother liquor storage tanks to facilitate on-site operation, saving labor and improving the working environment.

(7) paste barrel information label printing function

The system is equipped with an EPSON printer, which provides information about the production slurry through the control of the delivery operation software. After the distribution of the slurry, the label is printed, and the label is attached to the paste bucket to make each barrel of color paste Identification of labels to facilitate the management of residual pulp and improve the use of dyeing materials. The label information includes: prescription information, error information (refer to the error between the actual production use and the information provided by the sample recipe), the order number, the color number, the machine number, and the total liquid amount.

(8) Automatic color change calculation function

If you find that the actual product has a color difference with the sample, you can use the system's automatic color change calculation function. The amount of residual pulp is automatically weighed on the equipment electronic scale, and the capacity of the barrel and the formula data after the trimming are input on the operating software, and the software can automatically calculate the minimum amount of the new formula. At the same time, the components of the new formula can be increased or decreased.

(9) Intelligent mother liquor automatic circulation

In order to ensure the stability, uniformity and consistency of the dye mother liquor, the system can set the time of the mother liquor circulation and the interval of the cycle time according to the production needs.

(10) Automatic cleaning function of tank pipeline

The open source automatic pulping system is specially equipped with a corrosion-resistant conveying hose and an imported pneumatic diaphragm conveying pump to support the automatic cleaning function of the mother liquid tank, so that the customer can conveniently and quickly clean the tank and the pipeline.

(11) Residual pulp recycling function

In order to maximize the cost and reduce the waste of dyeing materials, the system has specially set the residual resin recycling function. In the case of an order of similar color to the customer, the computer can preferentially select the residual color of the similar color, and change the color of the formula of the residual pulp in the valid period, and confirm the color sample, then it can be formally used for production.

(12) database backup

Basic maintenance of the system database includes settings for setting the backup time, backup path, and so on.

(13) Data statistics function

The cost statistics of materials and the amount of pulp used by the pulper can be calculated according to the order, material, team, machine and user combined start time.

(14) Self-developed multi-stage flow distribution valve

The size and flow are integrated, the circumferential direction is arranged, the cylinder is swung, and the center is positioned and distributed, which can realize the beaker-level batching measurement.

5. Paste preparation system development purpose

Since many printing manufacturers still stay in the stage of manual paste adjustment, many problems have arisen. First, the paste is manually prepared, and it is difficult to sufficiently dissolve the paste in water. Even if it is stored for more than one day, it only makes the large particles smaller, and the small particles are soluble in water, and the uniformity and fineness of the paste are difficult to satisfy. The increasingly fine printing requirements are prone to dragging and blocking in the printing process. Second, since the paste is stored for one day to fully dissolve the paste in water, it affects the freshness of the paste. Thirdly, because the additives such as paste and urea are unevenly distributed in water, the coloring fastness is likely to be different during steaming, and even after finishing, the large color blocks of the printed cloth are not uniform. Fourth, the distribution of the paste in the water is uneven, and it is easy to cause desizing when washing, which affects the washing effect.

For the above reasons, we have developed a paste preparation system.

6. Paste preparation system features introduction

(1) Special and efficient beating tools greatly speed up the beating speed

The paste preparation system is specially equipped with two sets of high and low speed stirring paddles. The paste powder is weighed into the mixing tank after being weighed by the electronic scale. At the same time, the equipment automatically flushes the water into the beating barrel, and automatically controls the proportion of the water powder through the flow meter through high speed stirring. The paddle is quickly beaten and the powder is fully broken. After that, the paste is evenly stirred by the low-speed stirring paddle. The entire beating process saves time and effort. The beating time can be doubled compared to the traditional process, and it usually takes 25-30 minutes to complete the beating. At the same time, mechanical work has replaced manpower.

(2) Paste online filtration technology ensures uniform and delicate printing paste

The paste preparation system uses an in-line filter for beating mixing and slurry distribution, and uses a high mesh stainless steel filter to ensure that the formulated color paste meets the printing process requirements.

(3) High-viscosity paste conveying technology to realize automatic delivery of paste

The system adopts a thick slurry pump suitable for conveying high-viscosity medium, and cooperates with stainless steel pipes and valves to distribute the different proportioning pastes in the paste storage tank to the mixing and distributing head and the mother liquor, thereby obtaining the color paste required for printing. .

7. Use effect (taking Nantong Textile Holding Group Textile Dyeing Co., Ltd. as an example)

Economic benefit

(1) Accurate and perfect formula database system not only improves the speed of order making, but also reduces residual pulp and reduces the environmental pressure of enterprises. The problem of residual pulp is the biggest headache in the printing workshop. The traditional practice, because of the fear that the color paste in the printing process is not enough to add pulp will cause chromatic aberration, generally it is a one-time color paste that can print a complete order, but because of the error in the estimation of the pulp, there are many in Ningduo. Under the guiding ideology, the color paste is always done too much. After the final order is completed, the color paste becomes more residual. Most manufacturers use the black ink in the printing residue to make a black pulp and then use it. Either it will be dumped. However, the treatment of the residual slurry not only causes poor control of the mixed black color, but also poor color fastness, and the discarded residual waste wastes material and creates a burden for sewage treatment. . The residual pulp management function of the open-source printing color paste computer pulping system is very effective for the recycling of the residual pulp. The use of effective residual pulp reduces the cost of dyeing and reducing the cost of wastewater treatment. Of course, the most fundamental measure is to maximize the control of residual pulp. The utilization rate of color paste has increased from 81% before use to more than 90% now. The annual consumption of dyed materials is 11 million yuan, and the annual cost of single dyeing materials is 990,000 yuan.

(2) The system realizes all relevant data management of the pulping system, and implements unified management of equipment environmental factors and databases to ensure the reliability and stability of the process connection. The use of a fully automatic mixing system ensures inter-batch chromatic aberration and stability within the batch. The overall quality of the product is improved. The proportion of first-class products increased by more than 2%, which is estimated to bring up to 400,000 meters of first-class products in a year, which can create millions of value for the company.

(3) Shortened the sample operation process, reduced the number of proofs, and improved the quality of the product. The sample mother liquor is taken directly from the dye mother liquor tank, no need to carry out the chemical material, calculate the formulation, and the color paste modulation work. The high-precision electronic weighing system and the perfect formula library management system ensure the accuracy of sample and sample proofing, thus reducing the number of proofs and saving production costs. The color success rate decreased from an average of three times to an average of two times.

Labor benefit

(1) Powerful computer network control system greatly realizes resource sharing, reduces the number of operators, saves labor costs, and facilitates production management. The workshop's pulping staff has dropped 20% from the 15 people before use to the current 12 people. At the same time, due to the simple operation of the fully automatic pulping system, the dependence on experienced pulp mixers has been reduced. Avoiding the large loss of the company due to personal mobility, the estimated annual labor cost can be reduced by 40,000 to 50,000.

(2) Saving labor, improving the working environment, reducing labor intensity and improving production efficiency. The labor intensity of the pulping staff decreased from level III manual labor (three-level strength) to level II manual labor (two-level strength), which was reduced by one grade. The improvement of the software working environment ensures the stability of the staff in the pulping workshop, greatly mobilizes the enthusiasm of the workers, and indirectly improves the quality of the products.

Management benefit

(1) Complete and efficient computer formula management system. Due to the database recipe management system, the error between the sample and the sample is minimized, so that there is no deviation. It can quickly and accurately query historical recipe data, quickly make production plans, greatly improve production efficiency, and make the production process easy to manage.

(2) The accuracy of the color paste modulation is greatly improved, and the stability and reproducibility of the color shade are ensured. The reproducibility of the color paste increased from 85% to 95% before use, and the overall quality of the product went up a step.

Disperse printing is mostly used for polyester fabrics. It is a printing method in which the dye is sublimed by heat at a high temperature (about 200 ° C) to agglomerate on the surface of the polyester, and then penetrates into the amorphous region of the fiber macromolecule, and is fixed inside the fiber after cooling. The dispersion printing pattern has the characteristics of vivid pattern, fine color, clear layer, firm color fastness and strong stereoscopic effect.