Application Practice of High-tech in Mixing Workshop

I. Introduction

The printing and dyeing industry is a key industry for deep processing of textiles, fine processing, and increasing value-added, and it is a comprehensive embodiment of the development and technical level of the textile industry. With the continuous development of new textile printing and dyeing technologies and new technologies, textile printing and dyeing equipment is constantly being updated. At present, new equipments for printing, dyeing, printing and finishing are emerging in the printing and dyeing industry. Especially as the IT industry gradually enters the textile printing and dyeing industry, printing and dyeing CAD/CAM technology brings 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 to impede the improvement and development of printing and dyeing technology.

As China enters the WTO, the export of textiles will continue to increase. At the same time, international competition will become more intense. Therefore, the requirements for quality will also be more stringent. At the same time, the requirements for ecological protection in the world have made clean production and green consumption increasingly the mainstream of development. In the traditional printing and dyeing process, the mixing and color matching are performed manually, the accuracy is low, the accuracy is poor, the influence of human factors is large, the labor intensity is large, the operating environment is poor, the guidance of the sample for the large production is poor, and the technical files and data are entirely dependent on the artificial Accumulated experience and manual recording cannot achieve the computerized information management of technical files, and cannot complete the on-line call and verification of technical data. Therefore, in the production, there are often cases where the color is inaccurate or the sample does not meet the requirements, resulting in the need to return to repair to leave the factory, not only can not deliver on time, but also a waste of human and material resources. At present, the export products often require the left-right color difference, the standard for color difference in the batch is above 4.5, and the sample must reach the order of more than 4. The color light source is also developed from the original natural light, the office general 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 requirements of national standards; the other hand, due to the current color printing and dyeing industry Samples are still sampled according to the customer's specifications, and then the traditional method of magnifying the sample on the machine, the sample proofing and the technical personnel in the production dimming must be trained for a long time to be able to perform the dithering work, so to a greater degree It also depends on experienced technicians. With more frequent flow of talent, enterprise products will become unstable.

In order to reduce dithering, rely on human color, reduce the number of samples, and improve the sample level. Reducing the color difference between batches and the color difference within the batch due to the errors in the weighing during the production process. After repeated argumentation and absorbing the advanced experience of foreign printing and dyeing companies, Nantong Textile & Dyeing Group Co., Ltd. introduced printing and dyeing developed by Hangzhou Open Source Computer Technology Co., Ltd. Automatic computerized liquid dispensing system. Since its introduction into production in May 2006, it has been gradually accepted by workshop production. The number of samples during dithering is greatly reduced, and the color difference control is significantly improved. With this system, not only automation of color mixing and color matching, precise weighing of materials, but also functional modules such as cost analysis are integrated into this system, enabling enterprises to obtain more savings in cost reduction, improvement of management level, and improvement of product quality. More economic benefits.

Second, automatic printing pulping system introduced

1. Components

The open-source printing dyeing and mixing dyeing system consists of three parts: the ALICK blender, the paste making machine, and the ANCOLOR software.

ALICK Blender adopts product data management system and high-precision electronic scales. It has an independently operable production system and proofing system to ensure the consistency of proofing and production. It has computer storage recipe function and it is for returning single order and adding orders. The accuracy of color provides assurance. The system can use up to 50 kinds of mother colors and is fully computer controlled. Sample mixing the maximum amount of 30kg (configuration 34kg electronic scales), the production of the maximum amount of mixing 100kg (configuration 150kg electronic scales). The system is equipped with an automatic mixer and an automatic conveyor belt, which saves the use of labor and greatly reduces the consumption of dyestuffs, the largest consumable in the entire process. Not only increase the production efficiency, but also minimize the processing costs in the process of printing and dyeing.

ALICK's paste machine is a system for printing raw pastes. It is not only an independent original paste preparation system, but also can be connected with a fully automatic computerized pulp mixing system to complete the overall automation configuration of the printing adjustment plant. The system is a high-tech product integrating mechanical, electronic, precision weighing, database management and network technology. It has an independently operable computer management system, which automatically controls the viscosity of the original paste prepared, has a uniform mixing of water and powder, and adjusts the pulp to be used. To ensure the freshness of the printing paste, the fineness of the paste, saving dyes and improving the production efficiency.

ANCOLOR software is a full-scale computer management of the production process, formulas and materials for printing and dyeing products. According to the requirements of process recipes and order colors, the system can rapidly formulate the process and formula by calling the data of the system, which greatly improves the sampling rate of the proofing and production, reduces the proofing time, and ensures the production quality.

2. Development of a pulping system

The starting point for the development of this system is: With the continuous improvement of the quality requirements of the printing and dyeing industry, the production process flow must be considered in the design of a high starting point, the use of high-tech, high-efficiency system solutions. For printing/dyeing/dispensing, the key is to ensure the accuracy of the dyeing process recipe, to ensure the reproducibility of the process recipe, to reduce the process waste of the slurry preparation and to give full play to the production of the printing dyeing machine. Efficiency, and then to achieve the purpose of improving product quality.

3. Computer sizing system process

The production department computer enters the order information through the open source mannron database management software, and the information is stored in the server database; the process room passes the experiment, formulates the sample recipe and makes the sample, establishes the computer process recipe library, and can use the color matching software The color measured by the color matching instrument (such as spectrophotometer) is declustered and restored and stored in the database. The closest color is found in the formula library. The closest formula data is found and used directly or slightly modified to obtain new ones. Recipe, and continue to enrich the recipe library. The computerized pulping system and paste preparation system automatically calculate, modulate, distribute pilot and large-scale production pastes through the control of Manaslon's issuing software.

4. The main features of the mixing system

(1) Accurate color reproducibility and automatic color change function

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

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

The use of imported pneumatic diaphragm pump, swift and efficient mobilization of mother liquor, and the mother liquor to maintain one-way flow; At the same time, through the diaphragm in the pump to separate the mother liquor flow and the internal structure of the pump to ensure that the mother liquor does not contact the pump internal structure, extended The service life of the pump.

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

The use of imported raw materials to produce mother liquor storage tanks has a long service life. At the same time, large-tank storage is used for the production of commonly used dyes to increase the use efficiency.

(4) High-mesh filter to ensure the mother liquor does not contain impurities

The system is equipped with an in-line filter in the mother liquor distribution and recycling process. The filter is based on the printing and dyeing process, and adopts a high-mesh stainless steel filter to remove particulate impurities that do not meet the production process requirements, ensuring the purity of the mother liquor and greatly reducing The phenomenon of color point, filter cartridge assembly and disassembly and easy to clean.

(5) Specially designed stirring system features

A lifting device is designed for automatically raising and lowering the agitation slurry, so that the slurry is stirred up and down evenly. The fully automatic cleaning device enables the automatic cleaning of the mixing paddle, reducing the contamination of the work site and creating a good working environment.

(6) Mother liquid material feeding device

The mother liquor adopts the semi-automatic powder opening system and 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 material is added with water and accurately measured by the flowmeter to ensure the mixing ratio of the powder and the mixture is automatically fed after stirring. The devices and pipes are transported to the corresponding mother liquor storage tanks to facilitate on-site operations, save labor and improve the working environment.

(7) Slurry bucket information label printing function

The system is equipped with an EPSON printer. Through the control of the issuing software, it provides information on the production of the paste. After the paste is dispensed, the label is printed and the label is affixed to the paste barrel. Identification labels to facilitate slurry management and improve dye usage. Label information includes: prescription information, error information (refers to the error between the actual production use and the information provided by the sample recipe), order number, color number, machine number, and total liquid volume.

(8) Automatic color change calculation function

If there is a color difference between the actual product and the sample, the system's automatic color change calculation function can be used. Automatically weigh the remaining slurry on the equipment electronic scale, input the capacity of the barrel on the operation software and the recipe data after trimming, and the software can automatically calculate the minimum amount of new slurry for the new formulation. At the same time, each component 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 mother liquor circulation time and the cycle time interval according to the production requirements.

(10) Automatic cleaning of tank piping

The open source company's automatic pulping system has specially equipped corrosion-resistant transfer hoses and imported pneumatic diaphragm transfer pumps to support the automatic cleaning function of mother liquor tanks, enabling customers to conveniently and quickly clean tanks and pipelines.

(11) Residue Recycling Function

In order to save the cost to the greatest extent and reduce the waste of dyestuff, the system has specially set up the function of residual pulp recycling. In case of similar orders for customers, the computer can preferentially select the similar color of the residual slurry, and formulate the color change of the residual slurry within the valid period. After confirming the color change sample, it can be formally used for production.

(12) database backup

The basic maintenance of the system database includes the setting of the backup time, the backup path, and the like.

(13) Data Statistics Function

According to the order, material, team, machine, and user, the cost statistics of the materials and the statistics of the slurry used by the converters can be calculated according to the start time.

(14) Independently developed multi-stage flow distribution valve

Integration of size and flow rate, circumferential arrangement, cylinder swing, central positioning and distribution, can achieve beaker-level ingredients metering.

5. Paste preparation system development purposes

Due to the fact that many printing manufacturers are still in the process of manually adjusting the paste, many problems have arisen. First, manually modulating the paste makes it difficult to fully dissolve the paste in water. Even if it is stored for more than one day, it will only make the large particles smaller, and the small particles will dissolve in water. The uniformity and fineness of the paste will be difficult to satisfy. With increasingly elaborate printing requirements, drag marks and plugging are prone to occur during the printing process. Second, because the paste must be stored for one day to fully dissolve the paste, it affects the freshness of the paste. Thirdly, due to the uneven distribution of additives such as paste and urea in water, the color fastness during steaming is not uniform, and even after finishing, the large color block of the printed cloth is not uniform. Fourth, the uneven distribution of paste in the water, but also easy to cause desizing out when washing, affecting the washing effect.

Based on the above reasons, we have developed a paste preparation system

6. Paste preparation system features introduced

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

The paste preparation system is specially equipped with two sets of high and low speed stirring blades. The paste powder is weighed into the mixing tank after being weighed by an electronic scale. At the same time, the equipment automatically flushes water into the beating bucket, and the water powder ratio is automatically controlled by the flow meter through high speed stirring. The paddles were beaten quickly to fully break up the powder mass. Afterwards, the paste was stirred evenly with the low-speed stirring paddles. The whole beating process saves time and effort. The beating time can be reduced by a factor of two compared to the conventional process. Generally, it takes only 25-30 minutes to complete the beating. At the same time, mechanical work also replaced manpower.

(2) paste on-line filtration technology to ensure printing paste uniform and delicate

The paste preparation system uses an on-line filter for both beating and feeding, and uses a high-mesh stainless steel filter to ensure that the formulated paste meets the printing process requirements.

(3) High-viscosity paste transportation technology to achieve automatic distribution of paste

The system adopts a thick slurry pump suitable for conveying high-viscosity media. In combination with stainless steel pipelines and valves, the different proportioning pastes in the paste storage tank are distributed in proportion to the slurry distribution head and the mother liquor to obtain the color paste required for printing. .

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

Economic benefits

(1) Accurate and complete formula database system not only improves the speed of the system, but also reduces the residual slurry, which reduces the environmental pressure of the company. The problem of slurries is the biggest headache for the printing shop. Traditionally, due to the fear that the color paste will not be sufficient for the printing process and then add pulp to cause chromatic aberration, it is generally a one-time-use color paste that can print a complete order. However, due to errors in the evaluation of the slurry, there are quite a few of them. Under the guiding ideology, the color paste is always done in excess, the final order is completed, and the color paste becomes more slurried. Most manufacturers use black paste to make paste paste and then use it. Either it is drained. However, this type of slurry treatment causes both poor control of the color of the mixed black paste, poor color fastness, and waste of the spent slurry which also wastes material and creates a burden on the sewage treatment. This is actually a frustration for the manufacturers. . The paste management function of the open-source printing paste computerized pulping system is very effective for the recycling of the slurry. The effective slurry utilization reduces both the cost of dyes and the cost of wastewater treatment. Of course, the most fundamental measure is to maximize the control of slurry production. The utilization rate of colorant paste has increased from 81% before use to 90% or more of the current use. It has been calculated on the basis of annual use of RMB 11 million for dyeing and chemical materials, and a single dyeing material has saved costs of RMB 990,000 per year.

(2) The system has realized all relevant data management of the slurry mixing system, and unified management of the equipment environmental factors and database has been implemented to ensure the reliability and stability of the process convergence. The use of a fully automatic sizing system ensures the stability of the color difference between batches and the color difference within the batch. This improves the overall quality of the product. The proportion of first-class goods increased by more than 2%. It is estimated that the company will bring up to 400,000 meters of first-class fabrics a year, which can create millions of dollars for the company.

(3) The sample flow was shortened, the number of proofing was reduced, and the product quality was improved. The sample mother liquor is taken directly from the dye mother liquor tank, without the need for further sizing, calculation formulation, color paste modulation work. High-precision electronic weighing system and perfect formula library management system ensure the accuracy of sample and sample proofing, thus reducing the number of proofing and saving production costs. The success rate of color matching fell from an average of three times to an average of two times.

Labor benefits

(1) A powerful computer network control system has greatly achieved resource sharing, reduced the number of operators, saved manpower costs, and facilitated production management. The number of pulping staff in the workshop was reduced by 20% from the 15 people before use to the current 12 people. At the same time, due to the simple operation of the automatic pulp mixing system, the dependence on the experienced boring division was reduced. Avoid the large losses caused by personal mobility to the company. Estimated annual labor costs can be reduced by 4-5 million.

(2) Save labor, improve the working environment, reduce labor intensity, and increase production efficiency. The labor intensity of the pulping staff was reduced from Level III physical labor (Grade 3 strength) to Level II physical labor (Grade 2 strength) and decreased by one grade. The improvement of the software work environment has ensured the stability of the staff in the pulping workshop, greatly mobilized the enthusiasm of the workers, and indirectly improved the quality of the products.

Management benefits

(1) A complete and highly efficient computerized recipe management system. Due to the use of a database recipe management system, the error between sample and sample size is minimized and there is no deviation. It can quickly and accurately query historical formula data and quickly make production plans, greatly improving production efficiency and making the production process easier to manage.

(2) The accuracy of color paste modulation has been greatly improved, ensuring the stability and reproducibility of color shades. The reproducibility of color paste increased from 85% before use to 95%, and the overall quality of the product reached a new level.

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