High-speed and high-efficiency one-step pretreatment and wet cloth mercerizing machine

The one-step pre-treatment of printing and dyeing occurred as early as after the founding of the People's Republic of China. With the development of high-efficiency additives and high-efficiency equipment, it has been rapidly developed in recent years. Wet cloth mercerizing is difficult to control due to the moisture content of the fabric, and the problems of concentrated alkali permeation and automatic alkali concentration control are not overcome, and the dry cloth is more mercerized. When the dry cloth is mercerized, the fabric must be dried after the boiled and rinsed, and the steam is seriously polluted. Under the current energy shortage and rising energy prices, China has upgraded the construction of resource-saving society to implement the scientific development concept. The strategic height of building a harmonious society in an all-round way. Under the excellent situation of comprehensive clean production in China, tapping potential, saving energy and reducing consumption in the printing and dyeing industry has become the work goal of printing and dyeing workers. To this end, our company cooperates with printing and dyeing customers, combined with the current high-efficiency process and high-efficiency auxiliaries, jointly develops high-speed and high-efficiency one-step pretreatment and wet cloth mercerizing equipment and puts into normal production, and has achieved good promotion and application effects. The front of the same industry. Social and economic benefits are very significant.
First, high-speed and high-efficiency one-step pre-treatment and wet cloth mercerizing machine equipment process pure cotton fabric singeing immersion pile → into the cloth frame → (steaming tank + two-roll rolling mill) × 2 groups → flat washing tank → efficient rolling → Padding through the core high liquid feeder → (the latest type) double-layer practice drying box → intermediate feeding frame (centering device) → (steaming tank + two-roll rolling mill) × 5 groups] → flat washing tank → three rolls Rolling car→falling frame→(J-box customer-supplied)→feeding frame→dip tank→high-efficiency uniform rolling→rolling mill→stretching roller→three-roll rolling→stretching roller→dipping tank→two rolls Rolling mill→clothing mercerizing machine→two-roll rolling mill→de-alkali tank→two-roll rolling mill→(de-alkali steaming tank + two-roll mill)×2 groups→(steaming tank + two-roll rolling mill)×3 Group→Steaming box→High-efficiency rolling→Unloading frame→(J-box user-supplied)→Input cloth (including cloth inspection device), rolling and falling device II, high-speed and high-efficiency one-step pre-treatment and wet cloth mercerizing machine technology Process pure cotton fabric singeing and immersing pile expansion reaction → feeding frame → temperature 60 ° C hot water rolling → temperature 80 ° C hot water rolling → temperature 40 ° C hot water rolling → room temperature padding one-step liquid → new Core high feed solution (room temperature padding one-step method) Liquid) → 102 ° C saturated steam rapid preheating for 40 seconds → 102 ° C saturated steam reactor steaming 80 minutes → intermediate feeding frame (centering device) → temperature 90 ° C hot water rolling × 5 groups → temperature 80 ° C hot water rolling → Wet cloth → (J-box customer-supplied) → wet into the cloth → dip-impregnated light alkali → high-efficiency uniform rolling → three-roll rolling rolling concentrated alkali → stretch cloth roller → two-roll rolling rolling concentrated alkali → Stretching roller→light alkali pre-washing→clothing mercerizing machine 5 punching 5 suction→two-roll rolling mill→de-alkali tank→two-roll rolling mill→(de-alkali steaming box+two-roll mill)×2 group→(steaming Washing box + two-roll rolling mill) × 3 groups → steaming box → high-efficiency rolling → wet falling cloth → (J-box user-supplied) → feeding cloth (including cloth inspection device) rolling and falling cloth device III, high-speed and efficient One-step pretreatment and wet cloth mercerizing process review and solve technical problems 1. High-speed and high-efficiency one-step pretreatment process overview and technical problems solved The cotton fabric pre-treatment process has desizing, scouring and bleaching as three-step method, desizing , scouring and combining, and then bleaching is a two-step method. Desizing, scouring, and bleaching are one-step methods. The three-step and two-step processes are long, water, steam, and people are very unsuitable for current clean production. One-step method is not in place due to the development of additives in the early stage, the stability of additives is poor, the batch is poor, the quality of fabric pretreatment is unstable, and the quality of semi-products is poor. In response to these problems, our company and printing and dyeing customers and auxiliary enterprises have passed a series of process tempering screening. The technical research of the equipment is streamlined, and the process formula, process flow and equipment flow are optimized. It solves the problem of poor reproducibility of the quality of semi-products produced by cotton fabric pre-treatment. The production speed is 85 m/min, the semi-product hair effect is 10 cm/30 minutes, the whiteness is more than 80, and the cotton surface remains without cotton, which completely reaches the enterprise export. Quality standards required.
The long process from the three-step and two-step processes to the one-step short process relies on the perfect combination of chemical processes and equipment. The equipment is guaranteed by one-step process reaction conditions, and the process method is not mentioned here. How can chemical additives penetrate into the fiber evenly and thoroughly in the shortest time? The puffing reaction of cotton pectin, cotton seed shell and slurry requires certain temperature, time, saturated steaming humidity and other conditions. Guarantee. In addition, in order to ensure high speed and high efficiency, we must work hard at high speed to solve the reliability, synchronization and rapid process of the equipment. Detailed calculations and adjustments were made to the mop tension, the rolling pressure, the drag power, and the offside range of the elastic frame. It also solves the problem of expansion and wrinkling of the fabric from stacking to running. Therefore, the equipment process first solves the desizing hot water washing after the singeing and immersing pile, removes most of the slurry and impurities; rapidly lowers the temperature to suit the room temperature padding one-step liquid; multi-dip multi-rolling and applies the high liquid feeding device The one-step method liquid is quickly permeated through the core, and the dip-plated high-concentration liquid feeding machine (the latest type) features: the end plate is made of 3mm stainless steel plate, which is processed by laser cutting and CNC cutting board. The utility model adopts two-roll horizontal padding structure, adopts cylinders on both sides, and the pressure is separately adjustable, and a pre-dip tank is arranged underneath. The fabric is first impregnated into the pre-dip tank, and then gravity-rolled by a pair of rolls in the tank, and the pressure is 8 tons of re-rolling. Double rubber roller, the rolling point is in the liquid, and the material can be eaten under the vacuum under the liquid. The fabric is immersed immediately after rolling at the rolling point. Since the fabric does not run in the air, the fabric fibers do not enter the air, and the fibers do not swell. Therefore, under the action of vacuum negative pressure and swelling suction force, the liquid enters the inside of the fiber to achieve the penetration of the heart. The upper rolling point pressure is low, which is beneficial to the surface with liquid and enter the steamer. The multi-dip multi-rolling immersion liquid is fully transparent. Multi-dip two-rolling, to achieve vacuum in the fiber and liquid supply to the fabric surface, the liquid volume can be adjusted according to the fabric, up to l20%. Equipped with a circulating filtration self-cleaning system (dynamic filter box), indirect heating, temperature control. The high liquid supply system is equipped with a uniform working fluid application system, which can automatically control the application amount of five chemical additives through the PLC, and is equipped with an imported electric induction flow meter and a pneumatic regulating valve. Features: Dip through the core, with a uniform liquid, with a large amount of liquid. Advanced steaming design: Immediately after the fabric enters steaming, the fabric is directly sprayed with saturated steam to preheat it, so that it can quickly reach the steaming of the process temperature. In order to ensure the steaming condition, the structure inside the steamer is unique in terms of humidification and rapid temperature rise. the design of. In order to ensure high-speed, high-efficiency, high-temperature washing and water saving, the combined machine washing has made great innovations in energy saving and emission reduction: the high-efficiency steaming unit uses a roll-to-roll serpentine flow, a compartmentalized water wash, and a grid-by-grid counterflow system design. Backwashing of fabric washing liquid, poor concentration of washing liquid, easy to fabric clean, combined with bottom water level design, less water storage, faster heating, less steam, less heating time, high production efficiency, fast washing liquid, lotion High utilization rate. The design of the cleaning cleaning mechanism: the cleaning mechanism is adopted on the combined machine. Only the last one is added with water, and the unit is forwardly reversed by the unit, and flows back to the desizing water before the steamer, saving water, saving steam, and saving alkali; Integrated design: the fabric runs in the closed channel, does not cool in the air, the dissolved impurities on the fabric will not condense, easy to wash, the steam is sealed by the closed channel, effectively reducing the loss of steam run. Temperature automatic control system: design temperature automatic control system, precise temperature adjustment and control, not only guarantee process quality, but also save steam. Dynamic Circulating Filter Device: Design dynamic circulating filter oscillating spray system, high-flow smooth and powerful spray, enhance the exchange of fabric and washing liquid, and quickly remove a large amount of pulp and floating color on the fabric surface. The dynamic filter box is composed of a brush roller, a filter drum, a slag discharge tank, a box body, a transmission system, a circulation booster pump, etc., and the filter drum is used to filter the fibers in the washing liquid, the flocculent paste, and then the brush roller. It is also brushed into the slag discharge hopper and discharged from the outside of the tank to separate it from the washing liquid to ensure that the washing liquid is clean and avoid secondary contamination. Recycling the lotion greatly increases the water utilization rate, and the washing cycle reduces heating and saves steam. Rotary waste hot water heat recovery device: This device can exchange the heat energy in the hot waste water discharged after washing (the temperature of the hot liquid discharged is generally 60-90 ° C), and exchange with the newly added water. The temperature rises from the water source temperature to 50-72 °C. Due to the use of the labyrinth liquid heat transfer heat exchanger and the advanced heat exchange of the centrifugal water film surface heat exchange, the contact area of ​​the cold water and hot water is large, and the heat exchange is very sufficient. The exchange efficiency is as high as 90% or more. The first advantage is that the steam for washing and heating is reduced, the steam saving is very obvious, and the second is to prevent the high temperature of the discharged hot waste water and affect the biochemical treatment effect of the sewage treatment. The centrifugal liquid flow of the device and the rotating circumferential liquid flow are self-cleaning, so that the dirt in the washing liquid is difficult to contaminate the heat exchange surface, thereby avoiding scale and dirt deposition. The investment is cost-effective and the investment cost is recovered in two months. According to the process, the process adopts a reinforced process prescription, adds various high-efficiency auxiliaries, controls the appropriate alkali-oxygen one-bath reaction rate, and formulates and adjusts the process parameters temperature, time, vehicle speed, and chemical agent dosage.
2, high-speed and high-efficiency wet cloth mercerizing process overview and solve the technical problems cotton mercerizing from the dry and wet of the fabric is divided into dry silk and wet cloth mercerizing. Due to the long-term mercerization of the wet cloth, there is no problem of the core filament and the unevenness of the mercerization. The reason is that the wet fabric has uneven water content, and the concentrated alkali cannot penetrate completely and the penetration is uneven. For this reason, when the wet cloth is mercerized, the equipment aspect focuses on solving the problem of the lowest and uniform uniformity of the rolling allowance before the wet cloth is immersed in the concentrated alkali, and solves the problem that the concentrated alkali solution is difficult to be viscous and immersed. After the wet cloth is put into the cloth, the dip tank and the high-efficiency re-rolling are designed, which is the key to realize the wet cloth. In the dip tank, the test of water, light alkali, and concentrated alkali was carried out. Only at 170 g/L of pale alkali, the mercerizing enthalpy value was optimized, and the dipping tank was subjected to the grading and immersion of the condensed alkali. Rolling mill rolling rate is the primary condition for wet mercerizing. It has also been improved. The pressure regulating range is increased to make the rolling ratio as small as possible (about 60% is the best). The medium-solid rolling rolls are used to improve the deflection of the rolls. The left, middle and right rolling rates are uniform. Other equipment problems are dealt with in the same step. The process mainly solves the problem that the wet cloth concentrated alkali is difficult to penetrate. The process parameters were formulated and adjusted to be 200-230 g/L for caustic soda, 2 g/L for penetrant, 50 °C for soaking alkali, and 85 m/min for production speed. Mercerized semi-product test: The 钡 value is 120-136, indicating that the mercerization is sufficient. Attention should be paid to the problem: in actual production, it is necessary to check the rolling rate and uniformity of the rolling mill before the dilute alkali and the stability of the concentrated alkali, and try to get the best combination of boiled and mercerized. If stored too much, it will form a local air drying, resulting in uneven rear light.
Analysis of social and economic benefits 1. Comparison of one-step method and two-step method:
(1) The equipment covers a small area and saves 50% of the land.
(2) The machine is completed from singeing to retort and floating once, shortening the production delivery time by 70%, realizing small batch production, short and fast delivery.
(3) High speed and high efficiency, due to the increase of vehicle speed (from 60 m / min to 85 m / min), improve production efficiency and reduce costs by about 20%.
(4) The sewage discharge capacity is 6,000 tons/day, which is reduced to 3,000 tons/day, the sewage treatment cost is reduced by half, and the sewage discharge is reduced by half.
2, dry cloth mercerizing and wet cloth mercerizing comparison:
(1) The three-column drying cylinder dryer is omitted, and the steam saving is obvious. The daily consumption of steam can be about 24 tons, and the cost is 210 yuan/ton, saving 5040 yuan a day.
(2) After the boiled and rinsed, it will not be dried, and the refining and bleaching will not be washed away. When it is mercerized, it will continue to be washed off, which will make up for the lack of washing. In the design of the joint machine, the design of washing ability can be reduced. . If it is dried, the refining and bleaching of the refining plaque will be solidified. When it is mercerized, it cannot be puffed, and it is not easy to be washed off, resulting in uneven printing or dyeing, poor coloring and dyeing.
(3) The wet cloth mercerized fiber is puffed, the alkali is uniform, the product quality is uniform, the dyeing property is good, the fabric quality is high, and the qualified rate of the product is improved.
(4) Wet cloth mercerizing does not produce broken edges.
(5) Wet cloth mercerizing cloth width.
(6) High-speed and high-efficiency, due to the wet cloth silk core processing, the vehicle speed can be increased by 40%, the production efficiency is increased by 40%, and the cost of the dry cloth mercerizing is reduced by about 15%.
(7) The machine is combined with singeing, retreating and bleaching, and multi-step mercerizing, once combined, reducing intermediate links, short production cycle, high efficiency and high product quality, which is very suitable for current clean production requirements.
The application of the above technologies is in line with the national energy conservation and emission reduction cycle development economic policy, and has a wide range of social and economic benefits. Based on the production volume of 4.6 million meters per year of the customer's production line, the annual savings of steam, water, electricity, labor, etc. can save about 3 million yuan. The company shares 6 production lines, saving nearly 18 million yuan per year, bringing customers Great economic benefits, and market competitiveness has greatly improved. It was awarded the 2008 Excellent Energy Saving and Emission Reduction Enterprise by the Provincial, Municipal and China Textile Associations.

Medical Silicone products

Medical Grade Silicone,Liquid Silicone Rubber,Silicone Rubber Sheet Non Slip Medical,Medical Custom Silicon Products

Xiamen The Answers Trade Co.,Ltd. , https://www.xmanswerssilicone.com