Focusing on the differentiation of spandex for more than ten years, Xinxiang chemical fiber anchor set a "small goal"

Cherry blossoms on the red, willow leaves green pool edge. On April 6, Xinxiang Chemical Fiber Co., LTD. 's annual output of 30,000 tons of spandex project was successfully started, and the annual output of 40,000 tons of spandex project was successfully laid, with a total production capacity of 160,000 tons and 40,000 tons under construction. The production equipment of the spandex project with an annual output of 40,000 tons is more intelligent and green: the industry-leading unmanned and highly intelligent control system is adopted, and the process of "waste recycling" and "waste gas centralized treatment" is adopted, and the recycling rate is 99%.

In order to avoid homogenization competition, Xinxiang Chemical Fiber has been committed to the differentiation and functional development and production of spandex products for many years, providing the market with more diversified products with lightweight fabrics, promoting product iterations and upgrading, becoming a leader in the spandex industry and an excellent supplier of fine denier and differentiated spandex, and realizing the conversion of old and new energy. With "science and technology, fashion, green" to inject new momentum for the high-quality development of enterprises.

1. Anchor new areas to stimulate new vitality

Xinxiang Chemical fiber has achieved a magnificent transformation from scratch, from small to large, from weak to strong after several generations of egrets' diligent governance and innovation.  Entering the new development period, Xinxiang Chemical fiber has opened up a second production base, further consolidating the industry position of recycled cellulose fiber, continuing to deepen the fiber industry quality track, and constantly open up new areas, laying the foundation for the sustainable development of enterprises.

In order to better develop advantageous industries and enhance the competitiveness of enterprises, the leadership team of Xinxiang Chemical fiber has anchored the development direction of spandex projects with market prospects after a long time of brewing and research. Spandex, short for polyurethane fiber, is an important elastic fiber that is widely used in textiles such as shapewear, surgical bandages and swim wear. At that time, the United States DuPont, Germany Bayer, South Korea Taiguang and Japan's two companies spandex production capacity accounted for 70% of the world, while the domestic spandex development was slow, to the end of the 20th century only Yantai and Lianyungang two production enterprises, the output is only 15,000 tons, especially the multi-functional differential spandex mainly relies on imports.

With the continuous improvement of living standards, people's requirements for clothing comfort continue to improve, spandex has superior high elasticity and elastic recovery, which is other fibers can not replace the advantage, spandex consumption will have a significant and strong growth, the development of spandex has important economic significance.

Anchor the project implementation, roll up the sleeves to work. In 2003, Xinxiang chemical fiber with an annual output of 6000 tons of differentiated spandex project began construction, the first phase of the project was put into operation in September 2004, which opened the ice-breaking journey in a new field and became one of the earliest spandex production enterprises in China. Once the egret spandex came out, it quickly seized the market, increasing the income and competitiveness of Xinxiang chemical fiber, and the plan to expand the scale was implemented in 2007. Spandex phase II maintained the original construction of 8 production lines layout, in the new equipment and adjustment of part of the public works on the basis of technical reform, the annual output of 8000 tons of differential spandex production capacity, polymerization capacity has been fully developed, but also make the product performance indicators on the basis of the original further.

Innovation and development cannot be achieved alone, and partners are very important. Xinxiang Chemical fiber in the development of spandex and Zhengzhou Cosco Spandex Engineering Co., Ltd. reached a consensus on the initial cooperation in equipment technology, spinning channels, spinning components, PTMG tanks and MDI sinks and other equipment all realized the localization, coupled with the transformation of public works, saving nearly 200 million yuan of capital, production costs are greatly reduced, and product market competitiveness is stronger.

The annual output of 8000 tons of differentiated spandex project has achieved good market benefits, in order to further enhance the market competitiveness of the product and form a scale advantage. In September 2010, Xinxiang Chemical fiber began to build a continuous polymerization differential spandex fiber project with an annual output of 12,000 tons in two phases, which was completed and put into operation in October 2014. The production capacity of white heron spandex reached 20,000 tons, which realized the upgrading of spandex products and opened up new profit growth points, making the main business advantages of Xinxiang chemical fiber more prominent. It has consolidated the position of Xinxiang chemical fiber in the domestic textile industry.

2 Tracking advanced technologies to address import dependence

If the first decade of getting involved in spandex from 2003 is a bold attempt in a new field, then the second decade is to open the take-off of egret spandex, which has milestone significance for Xinxiang chemical fiber and even the domestic spandex industry.

Ten years of accumulation, so that Xinxiang chemical fiber production technology and product quality have reached the domestic leading level, egret spandex products have a good market reputation and market share, and temper a mature technology, honest and dedicated, young, lean and efficient technical personnel and production staff, for the egret spandex industry stable and efficient development has laid a strong technical and talent foundation. The leadership team of Xinxiang Chemical fiber pays close attention to the rapidly developing spandex market, constantly follows the development trend at home and abroad and international new technologies and new products, gives full play to its own comparative advantages, continues to force spandex projects, and solve the status quo that most of the differentiated spandex relies on imports, injecting new impetus into the transformation and upgrading of Xinxiang chemical fiber, promoting structural adjustment, improving the development quality and economic benefits.

Since 2014, it has invested in the construction of 2× 20,000 tons of ultra-soft spandex fiber project, which became the highest one-time investment project of Xinxiang chemical fiber at that time. In December 2016, the world's first 96 head spandex production line was completed and put into operation. In March 2018, the world's first "multi-spin" 120 head spandex production line was put into operation, focusing on the production of ultra-fine denier spandex products. In April 2019, the spandex project with an annual output of 40,000 tons was put into operation. Only during the "13th Five-Year Plan" period, spandex built a production line with an annual capacity of 80,000 tons, with a total production capacity of 120,000 tons, becoming the largest domestic monomer production capacity, the most advanced production technology and equipment of spandex production enterprises, further expanding the development field, lengthening the industrial chain, and Xinxiang chemical fiber spandex products have entered a period of rapid development.

Xinxiang Chemical Fiber also stopped production and relocated 20,000 tons of spandex production line of spandex branch plant, expanded new development space, and promoted the conversion of new and old kinetic energy of Xinxiang chemical fiber. Five years of development has made spandex one of the pillar industries of Xinxiang chemical fiber plate, and entered the domestic spandex industry with a large scale and influential production enterprise echelon, which plays a supporting and balancing role for Xinxiang Chemical fiber in combating the cyclical fluctuations of the industry and maintaining the long-term, healthy and good development of enterprises.

In September 2020, the newly laid annual output of 100,000 tons of high-quality ultra-fine denier spandex project is a key project in the "14th Five-Year" strategic plan of Xinxiang Chemical Fiber, and the construction and equipment installation of the second phase of the project are carried out in a three-dimensional fashion. The project was originally scheduled for full production in 2023, but it was completed two years ahead of schedule, with a total capacity of more than 200,000 tons.

3 Break through the core technology to start intelligent production

Xinxiang Chemical Fiber will be innovative through the production, management, environmental protection and new product research and development and other links, Xinxiang chemical fiber and COSCO Spandex reached a strategic cooperation, jointly explore and research and development of new technologies, advanced equipment, breakthrough a number of core technologies, with a number of domestic and international invention patents, Xinxiang chemical fiber to achieve the total change, structural change and quality change.

In 2003, Xinxiang chemical fiber force spandex field. At that time, the spandex production equipment in the industry was generally 32 heads or 48 heads, the construction of Xinxiang chemical fiber spandex project developed rapidly, the process equipment was constantly upgraded, the new technology of spandex production was promoted in Xinxiang chemical fiber, 96 heads, 120 heads of production lines were put into operation, and each project had a qualitative leap. In addition, the "120 ultra-fine spandex key technologies and complete sets of equipment" project jointly developed by Xinxiang Chemical Fiber and COSCO Spandex and Zhongyuan Institute of Technology, the overall technology has reached the international advanced level, won the first prize of science and Technology Progress of China Textile Association in 2020, and was included in the "14th Five-Year" development and promotion list of China's chemical fiber industry.

The first phase of the project with an annual output of 100,000 tons of high-quality ultra-fine denier spandex was laid in September 2020. The core technology and equipment adopted high consistency spandex polymer technology and device, and the molecular weight and molecular weight distribution of the polymer were controlled by near infrared online monitoring and advanced control system (APC). It can meet the different requirements for the aggregation structure of spandex fiber in weaving, dyeing and finishing, setting and post-treatment. The spinning technology adopts high-density spinning and high-speed winding technology, and the spinning speed can reach 1000m/min or more. The project also integrates the "5G+ industrial Internet", which makes the automation degree higher, the process more stable, the material and energy consumption lower, and the environmental protection more energy saving.

The intelligent production process is the core of the entire intelligent manufacturing of Xinxiang chemical fiber. With the goal of "single equipment automation, complete production line intelligence, comprehensive management intelligence", Xinxiang Chemical Fiber fully takes into account the development of automation and intelligence in the scheme determination and equipment selection of new projects, and has signed strategic cooperation with Shanghai Section Card and 22 CLP to jointly explore how to better apply 5G and other new generation information technology in traditional industries. Promote the transformation of the industry from traditional manufacturing to intelligent manufacturing.

The intelligent production line of Xinxiang Chemical fiber is closely integrated with DCS system, PLC system and WMS system, and the production can be controlled all weather. Spandex products under the control of APC program can achieve automatic wire fall, the use of RFID technology to record product information, after the robot is transported to the automatic sorting line by the AGV handling robot, under the traction of the mechanical arm, packaging, labeling, warehousing, in one go, the whole line from the wire fall, sorting, packaging, labeling, warehousing automation. The labor intensity of the entire production line is greatly reduced, the working environment is better, the production process is more stable, and the monitoring and tracing of product quality can be controlled. Xinxiang Chemical Fiber won the title of "the first 5G smart Factory in Henan Chemical Fiber Industry", "Industrial Smart Factory in Henan Province", "Intelligent Manufacturing Benchmarking Enterprise in Henan Province" and "Excellent Practice Enterprise in China's Industrial Digital Construction in 2020-2021".

4. Focus on differentiated research and development to increase green development

With the continuous increase of domestic spandex production capacity, the market competition is becoming increasingly fierce. In order to avoid being involved in low-end, homogenized competition, Xinxiang Chemical fiber in the use of new equipment, new processes, improve product quality and reduce costs at the same time, the use of their own provincial R & D platform, the organization of research and development team focused on ultra-fine denier, differential fiber production and research and development, with downstream enterprises collaborative innovation, open up new areas of spandex use, to stimulate consumption with bright points, guide consumption, Carve out a new world of your own.

Egret spandex products have experienced a change from "let customers use" to "let customers use good", and strive to achieve irreplaceable products. Nowadays, the white heron spandex has the characteristics of high elongation, high stress, high resilience, high uniformity, etc., and can also produce differentiated spandex products such as chlorine resistance, high temperature resistance, oxidation resistance, easy shaping, dyeing, renewability, and antibacterial according to different uses, to meet the special needs of various textiles, and the application field is more extensive.

In recent years, with the promotion of the advantages of Xinxiang chemical fiber spandex products and the layout of overseas markets, the foreign market share of egret spandex has been rising. In the past, the European market high-end knitted fabrics, high-end women's wear and high-end woven socks and other products used in the spandex mainly from South Korea Hyosing and Laika two companies, domestic spandex companies rarely able to enter the European high-end textile market. In 2019, by virtue of product quality and customers' trust in the "egret" brand, Egret Spandex became the first company in China to steadily and continuously export spandex products to Europe.

Standing at a new starting point, Xinxiang Chemical Fiber adheres to a high-quality development strategy. Focus on the main business of fiber, continue to implement intelligent manufacturing as the main starting point, use the new technology and new raw materials of spandex production to improve the ability of key technical equipment and improve the level of green manufacturing; By increasing the research and development of ultra-fine denier, differential and green spandex, expand the use of spandex in traditional application fields and emerging application fields, create a new competitive advantage of spandex in the industry, and help the green and sustainable development of the industry.