Shaoxing Keqiao'S Transformation "Trio" Provides New Solutions For The Textile Industry

The global textile industry is at an important juncture of transformation and development. The traditional high energy consumption and high pollution production mode is facing elimination. The deep integration of digital technology and the textile industry has become a new development direction to promote the industrial chain to become intelligent and high-end. Keqiao District, Shaoxing City, Zhejiang Province, as the core cluster of China's textile industry, has more than 8000 textile enterprises, and textile trade covers 206 countries and regions. Their innovative practices are providing new solutions for the transformation of the global textile industry. 　

"In order to increase the sense of hierarchy of the uniform equipment of the Chinese sports delegation, we rely on AI technology and use digital printing technology on functional nylon fabric to make the clothes look more dynamic and fashionable. ”In Keqiao District, Shaoxing City, Zhejiang Province, said Xiao Xingshui, general manager of Qianyong Textile Co., Ltd.

Last year, his company deployed the perfect gradual change of "national flag red" and "classic red" with AI algorithm. It took only four months to complete the production task of award-winning clothing printing for the Asian Winter Games, and the clothing design also stepped on the stage of the opening ceremony.

At present, the global textile industry is at an important juncture of transformation and development. The sense of technology and fashion behind the rolls of cloth also witnessed the transformation and upgrading of Shaoxing Keqiao textile industry. In this land that holds one third of the world's textiles, a group of textile enterprises have enabled textile reform with AI technology, reshaped the industrial background with green and low-carbon, and promoted innovation with the cluster industrial chain, playing a "trio" of industrial transformation.

　　 When printing and dyeing has "brain"

AI is launching a "smart manufacturing revolution" in the digital factory of Qianyong Textile. 11 high-precision digital printing devices control the printing error within 0.1mm through AI image and text processing technology. "The new technology makes the red gradient effect of the clothing for the Asian Winter Games exceed the limits of traditional technology." Xiao Xingshui pointed to the production line and explained, "This system can automatically identify the fabric texture, optimize the printing path, improve the production efficiency by 40%, and shorten the order delivery cycle by 50%." At present, Qianyong Textile has begun to prepare relevant clothing orders for other important events.

"As the digital general contractor and industrial consultant of the textile, printing and dyeing industry, we are deeply aware of the necessity of digital and intelligent transformation of enterprises," said Luo Yucheng, deputy general manager of Shaoxing Keqiao Weaving, Printing and Dyeing Industry Brain Operation Co., Ltd, "In the traditional workshop production mode, the process is highly dependent on manual operation, and the quality control is mostly based on empirical judgment, which is difficult to ensure the accuracy of each operation. Digital transformation services can significantly reduce the product quality problems caused by human errors, while optimizing the scheduling production plan and improving production efficiency."

Technological innovation goes beyond the production side. In the printing and dyeing industry service center of Keqiao District, the "digital twin factory" module in the brain of the weaving, printing and dyeing industry is operating effectively. The actual business and production scenarios are simulated, analyzed, tracked, compared, calculated, and the product quality, cost and other information are tracked throughout the process. "Our digital twin visualization system can provide data support for enterprise managers to make decisions," said Luo Yucheng.

"The industrial brain takes the industry demand as the traction, explores the path of data element collaborative optimization, reuse and efficiency enhancement, and has achieved gratifying results in the three aspects of economy, society and data elements." Luo Yucheng said that in 2024, the industrial brain will integrate 189 applications (including more than 110 applications and industrial APPs issued by more than 40 service providers), More than 130 digital application scenarios, including more than 30 multi cross application scenarios and industrial chain collaborative applications, increased by more than 50% over the target number of the previous year.

　　 When "green" technology is integrated into the printing and dyeing industry

The traditional printing and dyeing industry is characterized by high energy consumption, high pollution, high emissions, and low-quality and extensive production and operation, making the industry stand on the cusp of the storm. Data shows that in 2009, Keqiao District dyed 15.6 billion meters of cloth, with a profit of only 1.3 billion yuan, earning only 8 cents per meter on average, but consuming 12.7 kilograms of water.

Since 2010, Keqiao has started the implementation of the printing and dyeing industry cluster upgrading project. In accordance with the positioning of "green high-end, world leading", it vigorously promotes equipment upgrading, green development, innovation driven, fashion leading, digital, intelligent, clean transformation and upgrading, "water-saving dye vats", "waterless dye vats", "digital printing and dyeing", and "reclaimed water reuse" And a batch of high-end equipment and advanced technology were applied.

In the process of green transformation, many textile enterprises in Keqiao have crossed the sea and demonstrated their respective talents.

Today, the printing and dyeing workshop of Zhejiang Yingfeng Technology Co., Ltd. in Keqiao District Economic and Technological Development Zone can't see sewage and smell peculiar smell. Nearly 50 printing and dyeing machine cylinders operate in order, and only a few staff members shuttle among them. Workers only need to touch a few keys, and the machine cylinder can automatically start dyeing.

"The ratio of digital equipment in our factory has reached more than 90%, the production cost has been reduced by about 20%, the production cycle has been shortened by 30%, and the energy consumption has been reduced by about 20%." Xu Yegen, deputy general manager of Zhejiang Yingfeng Technology Co., Ltd., listed a series of figures, "the one-time success rate of printing and dyeing has increased by nearly 15%".

Shaoxing Hantu Textile Co., Ltd. is committed to the research, development and production of environmentally friendly renewable products, and its environmentally friendly renewable products account for up to 40%. "The recycled fiber we currently use, which uses recycled plastic bottles or old clothes as raw materials, is transformed into recycled textile materials through special treatment. In this way, it not only reduces the landfill of printing and dyeing solid waste, but also reduces carbon emissions. We are accelerating the introduction and application of recycled environment-friendly fabrics to production. At present, we have worked with ZARA Wal Mart, Anta and other well-known brands have reached cooperation to help global environmental protection. ”Zhu Yu, general manager of the company, said.

"Now, green high-end is our biggest competitiveness." Pu Jianfeng, head of Zhejiang Yuexin Printing and Dyeing Co., Ltd., said that more than half of the company's orders are from the European and American markets, and the added value per meter of cloth is more than 3 yuan. "Over the years, we have basically obtained the printing and dyeing qualification certification of some world fashion chain brand organizations," said Pu Jianfeng.

　　 When the industrial chain goes out of the road of characteristic innovation

Keqiao is thriving because of cloth, constantly digging into the "cloth" and creating a hundred billion level textile industry cluster. Cluster development is an important driving force to promote Keqiao textile industry from small to large and from large to strong. It not only improves the overall competitiveness of the regional industry, but also promotes the win-win cooperation and complementary advantages of SMEs.

Keqiao now has more than 8000 textile enterprises, and the textile trade covers 206 countries and regions. From the upstream polyester fiber, chemical fiber raw materials, manufacturing enterprises form the cornerstone of the industry, supporting the province's chemical fiber production capacity advantage of nearly half of the national production capacity, to the middle reaches of the weaving, printing and dyeing (accounting for 40% of the national production capacity), to the downstream clothing, home textile and home furnishing and other end product manufacturing, matching creative design, service trade and other extended formats, Keqiao Textile has a complete industrial chain and market production and marketing system.

"In the past, every enterprise focused on its own product areas to ensure a certain profit. However, the current market situation has undergone tremendous changes." Zhu Yu sighed.

Relying on the characteristics of the industrial chain, Hantu Textile has carried out close cooperation with upstream and downstream enterprises to jointly develop innovative functional fabrics. By opening up the whole graphene industry chain, it has achieved comprehensive coverage from ore procurement, fiber research and development, spinning and weaving to garment design, and has created a unique innovation path.

"We jointly developed with the National Graphene Innovation Center to add graphene powder into renewable textile materials through special production processes, so as to enhance the functionality of fabrics from the source. At present, it has been widely used in sunscreen clothing, yoga clothes and other products, and has been highly recognized by the market. The application field of graphene fabrics is also expanding." Zhu Yu said proudly, "This mode of close cooperation throughout the industry chain ensures the improvement of R&D efficiency and autonomy, and also provides us with more possibilities in product innovation." (Reporter Zou Tiran)

(Source: Workers Daily)