Jet vortex spinning technology is a new spinning technology developed by the Japanese company Murata. It has been more than ten years since it was developed and put into the market, and it has been mainly used in the European and American markets. According to data, rotor spinning accounts for 34% of short-fiber spinning in the United States, and air-jet spinning and vortex spinning account for 28%. The sum of the two exceeds the proportion of ring spinning. This is mainly because it has the advantages of high efficiency, labor saving, clean production and low processing costs.
This technology has only been introduced in my country for four or five years. The vortex spinning technology was first introduced in Dezhou Huayuan, Shandong, Jiangsu Yueda, Dasheng, Chinatex Jinwei, and Xinjiang Chang. Heng and a few other companies use it to produce new vortex spinning yarns with cellulose as the main raw material (viscose, Tencel, Modal). Due to the unique yarn structure, high production efficiency, low labor requirements, and higher price than similar ring-spun yarns, vortex spinning has attracted great attention from textile enterprise operators in Zhejiang Province.
Vortex spinning has developed rapidly
Zhejiang is located on the southeast coast and has market information and industrial structure. The advantage of quick adjustment. Starting from 2009, according to the development trend of the market, Zhejiang needs to expand its knitted product processing capacity; at the same time, Zhejiang is one of the areas with a labor shortage, so it must use as few workers as possible while expanding its processing capacity. In the Xiaoshan area of Hangzhou, there has been an adjustment in the industrial structure, the opportunity to transfer shuttleless looms to large knitting machines, and a strong demand for non-cotton knitting yarns. Based on the above factors, business leaders in Xiaoshan area have accelerated the introduction of air-jet vortex spinning technology and the development and production of non-cotton knitting yarn through research, inspections and exchanges.
In the past two years, more than 100 vortex spinning machines have been put into production in the Xiaoshan area of Hangzhou, starting from spunbond knitting yarn and currently developing t/r yarn. Multiple varieties. Today, Zhejiang Province’s vortex spinning accounts for more than 2/3 of the country’s vortex spinning production capacity, becoming the province with the most imported air-jet vortex spinning machines and the largest output of air-jet vortex spinning yarns.
Due to the air-jet vortex spinning mechanism, the yarn structure is an inner and outer covering yarn, which is composed of a core yarn and an outer covering yarn. Except that the yarn strength is slightly lower than that of ring-spun yarn, other quality indicators, such as hairiness and yarn defects, are better than ring-spun yarn. In particular, the covered yarn structure has less hairiness. After being processed into a knitted fabric, the anti-pilling performance of the fabric is improved, and problems such as twist and weft bias of the fabric are better solved, thereby improving the quality of post-processing production. and production efficiency. Therefore, yarn produced by air-jet vortex spinning has been welcomed by more and more needle cotton knitting enterprises, and the market demand is expanding.
In addition, a core-spun yarn device can be installed on the vortex spinning machine to produce vortex-spun core-spun yarn, which increases the variety of vortex-spinning yarns and further expands its use. .
Production efficiency has been greatly improved
The maximum design speed of Murata’s air-jet vortex spinning machine is 450 meters/ Minutes, the current actual operating speed of Zhejiang enterprises is between 340 and 400 meters/minute (due to different raw materials and production varieties), which is 16 to 20 times the ring spinning speed (the average ring spinning speed is about 20 meters/minute ), which is 3 to 4 times the rotor spinning speed (the current spinning speed of rotor spinning is 80 to 130 meters/minute). Since it is improved on the basis of air-jet spinning technology, its spinning speed is about 100 meters/minute higher than that of air-jet spinning. Each air-jet vortex spinning machine currently has 80 spindles. Using 8 vortex spinning machines (640 spindles) can be equivalent to the production volume of 10,000 ring spinning spindles. The air-jet vortex spinning machine is the most productive machine among current spinning equipment.
At present, most air-jet vortex spinning enterprises use combined blowing and carding machines (a few are blowroom and carding machines). After the drawing process (three combined processes), Spinning yarn directly and making it into package yarn eliminates the roving and winding processes of ring spinning and realizes the integration of roving-spun yarn-winding, which is the shortest spinning process at present. Due to the high production efficiency of air-jet vortex spinning, the short spinning process, and the high degree of automation of the spinning machine (capable of automatic splicing and automatic doffing), it can not only reduce the labor intensity of workers but also save labor. The entire process of 8 air-jet vortex spinning machines The configuration (equivalent to 10,000 ring spinning spindles) only requires about 25 people (three shifts of operation).
The larger Zhejiang Tianchang Textile Company has 30 vortex spinning machines and only uses 80 workers, which is equivalent to only 20 people per 10,000 spindles. Ring spinning currently employs 80 to 100 people per 10,000 spindles, so its labor productivity is 3 to 4 times that of ring spinning. Producing more products with less labor is one of the important measures to solve the current recruitment difficulties of textile enterprises. It is also one of the reasons why Zhejiang textile enterprise operators develop vortex spinning.
The vortex spinning machine has advanced quality control methods. The machine is equipped with msc (electronic yarn clearer) or msc-f (contamination control) and vos (visual intelligent main control computer system). The combination of the two not only realizes online quality management and control, but also realizes simple preparation. Centralized management effectively ensures the stability of yarn quality.
Cost advantage is still the key
Since labor-intensive production and conventional product production are already in a low-profit situation, the current traditional textile industry urgently needs to shift from labor-intensive to technology-intensive, and from conventional yarns to differentiated and multi-functional new yarns. Since vortex spinning technology has the advantages of high production efficiency, short production process, labor saving, and unique products, its promotion and application can obtain better economic benefits for enterprises. According to preliminary analysisAnalysis: The last vortex spinning production line is equipped with 8 vortex spinning machines and corresponding blowing and carding units, draw frames and other pre-spinning equipment (equivalent to 10,000 spindles of ring spinning production capacity). The investment in main equipment is about 20 million yuan. , compared with the new 10,000-spindle ring spinning equipment investment, it only increased by about 3 million yuan (ring spinning uses equipment with automatic doffing long car and tray-type automatic winding machine). However, due to the high equipment efficiency and fewer equipment of the vortex spinning production line, its factory area can be saved by at least 1,000 square meters compared with the ring spinning production line, and it can save 1 million yuan in construction investment costs. Therefore, from the analysis of construction investment, the upper vortex spinning production line only requires 10% more capital investment than the upper ring spinning production line.
Due to factors such as labor saving and low energy consumption of the vortex spinning production line, the processing cost of vortex spinning is lower than that of ring spinning from the analysis of operating costs after being put into production. According to the actual operation data of enterprises that have been put into production in Xiaoshan area, when spinning 30 counts of viscose fiber yarn, the processing fee per ton of yarn in air-jet vortex spinning is 1,600 to 1,700 yuan, while the processing fee per ton of ring spinning is 2,500 to 2,600 yuan, with a difference of 900 Yuan / ton. Calculated based on a vortex spinning production line (8 units
At the same time, due to the unique quality of air-jet vortex spinning yarn, its selling price can also be slightly higher than that of ring spinning yarn of the same specification. The labor force is significantly reduced, the processing cost is reduced, and the selling price is increased to a certain extent, allowing enterprises to obtain better economic returns. These are important reasons for the rapid development of vortex spinning production capacity in Zhejiang in recent years. </p
