针织物平幅连续漂白系统（冷堆）染色前处理 、绳状固色制软后处理设备介绍 Introduction of Dyeing-and-Finishing Machine

• Open-width Continuous Bleaching System (Cooled Pad-Batch) for Knitted Fabric

• Pre-treatment in Dyeing Machine• Post-treatment of Rope Color-fixing Softer

陈学平Xueping Chan江阴金田机械有限公司开发部Jiangyin Jintian Machinery Ltd. - Development Dept.福田实业（集团）有限公司全资附属机构A wholly owned subsidiary of Fountain Set (Holdings) Ltd.19.10. 2011

• 集团简介 Group Profile

• 针织物平幅冷堆前处理设备介紹 Knitted Fabric Open-width Cold Heap Pre-process Equipment

• 绳状固色制软后处理设备介紹 Rope Color-fixing Softer Post-process Equipment

节能 高效 智能化Energy-saving High efficiency Intelligence

讲座简介 Seminar Outline

• 世界最大的圆筒针织布生产商之一 One of the world’s largest circular knitted fabric manufacturers

• 高度垂直综合服务包括：棉纱、染纱、缝纫线、针织布、染色、印花、整理、生产及成衣销售、制造及销售纺织机械等

Highly vertical integrated operations cotton yarn, dyed yarn, sewing threads, knitted fabric, dyeing, printing, finishing, production and sale of garments and textile machinery

• 向超过 40 个国家的成衣制造商提供布疋，以制成国际知名品牌的成衣 Major knitted fabric supplier to garment manufacturers in over 40 countri

es that supply to internationally renowned retail brands

集团简介 Group Profile

• 1969 年于香港成立， 1988 年于香港联交所上市 Established in Hong Kong in 1969. Listed in the Stock Exchange of

Hong Kong Ltd. (SEHK) in 1988

• 2010 财政年度之营业额超过 61 亿港元 2010 fiscal year turnover: over HK$6.1 billion

• 全球聘用雇员超过 15,600 人 Globally staff force of over 15,600 - 香港 HK： 3% - 中国 PCR： 88% - 海外 Overseas： 9%

集团简介 Group Profile

• 总部设于香港，在中国、斯里兰卡及印度尼西亚设有生产设施 Headquartered in Hong Kong; production facilities in China, Sri

Lanka and Indonesia

• 海外市场推广办事处 / 代表处分布 5 个城市 Overseas marketing/ representative offices in 5 cities worldwide

• 对节能环保、清洁生产方面非常重视并加大了该方面的研发力度 Energy Conservation and Environmental Protection are our top

priority

集团简介 Group Profile

江阴金田机械有限公司（簡稱「金田」）About Jiangyin Jintian Machinery Ltd. (“Jintian”)

公司介绍 Company Profile

• 近年研发出节能环保的新型染整设备，在多家附属公司的染厂广泛应用 Developed wide range of energy-savings and environmental

protecting equipments in dyeing and finishing, which are widely used in dyeing subsidiaries

• 金田有多家大型染厂的技术支持和试验平台，研发的设备均能达到当今节能环保的要求

With the technical support of many large-scale dyeing mills, our R&D equipments are able to meet the strict energy conservation and environmental protection requirements

冷堆前处理Cold Heap Pre-process

冷堆前处理背景 Cold Heap Pre-process Background

冷堆技术在针织物方面应用的快速發展：The significant development of cold heap technology in knitted fabrics:• 近年国家对节能減排、清洁生产高度关注 Due to Nation’s high concern on energy conservation, emission

reduction in recent years• 企业对降低成本有迫切需求，很多科研机构和企业也着重这方面的研发 Enterprises have urgent cost reduction need, which cause many

scientific research institutions and enterprises to develop it

冷堆工艺比较成熟，但真正应用到生产上还有许多技术难题要克服Cold heap is a relatively mature technology, but when applying to

production, there are still many technical problems to overcome

针织物平幅冷堆前处理设备介绍Knitted Fabric Open-width Cold Heap Pre-process Equipment

浸液槽Liquid Tank

入布对中装置Fabric

Centralizing 布出折叠装置Fabric Folding

轧车Padder

过滤器Filter

加料桶Refill

Barrels

浸轧部分 Padding

蒸洗部分 Steam Cleaning入布对中装置

Fabric Centralizing

汽蒸装置Steaming

洗水装置Washing

布出折叠装置Fabric Folding

预热装置Pre-heating

对中装置Centralizin

g

中和装置Neutralizin

g

轧车装置Padders

轧车装置Padder

加料桶Refill

Barrels

过滤器Filter

针织物平幅冷堆工艺要求及 5 个阶段5 Main Stages of Knitted Fabric Open-width Cold Heap Production and its Requirements

阶段 Stages

时间 Time 温度Temperature

轧液率Liquid

Rolling Rate

湿度Humidity

pH 值pH

Value

1. 浸轧 Padding

8

( 秒 sec)

- 120%-130% - -

2. 堆置Yarding

4

( 小时 hrs)

25-30℃ - 65% -

3. 汽蒸 Steaming

10-15

( 分种mins)

95℃ - - -

4. 水洗 Washing

- 60-80℃2洗 2 轧

Wash & roll for 2 times

- - -

5. 中和Neutralization

- 常溫Normal

temperature

- - 6.5-7.0

工艺流程 Production Process

浸 短时间內完成织物对处理液的吸附与均匀扩散To ensure the liquid are being absorbed and spread evenly in short time

第一步 浸轧 Stage 1 Padding

一半浸泡一半淋浴的好处：The benefits of half-soaking and half-showering:• 保证处理液的均匀 Ensure liquids are evenly spread• 操作安全，料桶配有自动感应装置 Safe operation, barrels are equipped with automatic sensors• 减少人手及成本 Save manpower and cost

加料桶Refill

Barrels

浸液槽Liquid Tank

淋浴槽Shower Tank

第一步 浸轧 (续 ) Stage 1 Padding (Cont’)

采用特殊的设计去控制张力和卷边，确保织物的轧液率均匀Adopt specially designed structure to control tension and roll edge

轧车Padder

均匀轧车保障轧液率均匀Padder ensures rolling liquid rate is even

扩幅板装置Extension Device

螺旋扩幅滾Spiral

Extension Roll

第一步 浸轧 (续 ) Stage 1 Padding (Cont’)

达到增溶、乳化、皂化、分解、氧化、溶胀Concentration , Emulsion, Saponification, Decomposition, Oxidation, Swelling

处理液中的碱剂与表面活性剂、双氧水缓慢地与织物上的杂质、色素反应The alkali and surface active agent of the liquid and hydrogen peroxide slowly react to

the impurities and pigment

将密封的布车堆放好Place sealed fabric trolley in stacking area

排列堆放 4 小时Piled up for 4 hours

第二步 堆置 Stage 2 Yarding

蒸 为快速催化的工序，加速双氧水的分解活性，令堆置时间大幅缩短，提高生产效率Steaming is a quick catalytic process -> accelerates decomposition activity of the hydrogen peroxide, shorten yarding time and improves production efficiency

织物在汽蒸的状态Knitted Fabric

under Steaming

第三步 汽蒸 Stage 3 Steaming

织物入蒸箱前配有预热装置，降低了织物在进入蒸箱的温差，避免织物瞬间产生的温差影响织物品质Preheating device reduces fabric’s temperature difference when enters steam box and prevents adverse effect caused by temperature difference

在汽蒸的过程中有两道翻动织物的装置来保证汽蒸均匀Two rolling knitted fabric devices to ensure steam are even

第三步 汽蒸 (续 ) Stage 3 Steaming (Cont’)

洗 是将已经分解、降解、乳化后的杂质通过连续的溢流清洗分散在水中，并将织物身上的残留物全部洗净，达到半成品要求Washing place decomposed, degraded and emulsification impurities in continuous cleaning water. It washes residues away and meets the semi-finished products requirements

第四步 洗水 Stage 4 Washing

• 通过先进的张力控制系统保障织物的张力 Advanced tension control system ensures elastic of fabrics• 下有振荡打水滚筒，上有四道喷淋 Water roller for oscillation beneath and four sprinklers above• 提高了水的利用率，降低了水的需求量 Improve water utilization ratio and save water

振荡打水滚筒Oscillation

Water Roller

张力控制器Tension Control System

第四步 洗水 (续 ) Stage 4 Washing (Cont’)

通过均勻的补酸使布面 pH 值保持在 6.5-7

Adding acid evenly to keep fabric’s pH value at 6.5 - 7

pH值探测仪pH Value Detector

第五步 中和 Stage 5 Neutralization

操作智能化 Operation Intelligence

• 智能化触摸屏控制界面﹐方便操作 Intelligent touch screen computers are user-friendly• 同步张力控制系统保证织物低张力运行﹐防止织物拉伸变形 Synchronized tension control system ensures fabric operates in low tension process and prevents it stretches or deforms

变频器Frequency

Converter PLC

好处 Advantages ：• 减少人为因素造成的损失，降低人工 Reduces the loss caused by human factors and labour cost

• 可长期保存生产数据，如时间 、机速、温度、用水量、助剂用量等 Long-term preservation of production data, such as time, speed, temperature, water consumption , additives dosage, etc.

工控电脑Intelligentcomputer

操作智能化 Operation Intelligence

05

101520253035404550

耗水（L/kg） 耗电(kwh/T) 耗汽（kg)

传统工艺前处理Traditional Pre-processing冷堆前处理Pre-process ofCold Heap

冷堆设备前处理与传统工艺前处理相比Water, Electricity & Steam Saving Comparison between Pre-process of Cold Heap and Traditional Pre-processing

省水 Water Saving 14.2L/kg

节省Saved

64.2%

省电 Electricity savings 22 kwh/t 45.8%

省汽 Steam savings 0.98kg 69.5%

对比项目 Contrast project

工艺处理 Production Process

传统前处理Traditional Pre-

processing

冷堆前处理Pre-process of Cold Heap

温度 Temperature 95℃25-30℃ 堆置 Yarding95℃汽蒸 Steaming

加工方式 Processing method

绳状 Rope 平幅 Open-width

白度值 White degree value

/ 接近 Similar

pH值 pH value / 7-8

冷堆前处理与传统前处理效果对比Comparison between Pre-process of Cold Heap and Traditional Pre-processing

对比项目 Contrast project

工艺处理 Production Process

传统前处理Traditional Pre-

processing

冷堆前处理Pre-process of Cold Heap

吸水性Hydroscopicity

-接近 Similar

30杪以内 Within 30 sec.

毛效Fur effection

-接近 Similar 7-10cm/30min

成品规格Finished product

specifications - 接近 Similar

处理方式 Treatment 剧烈 Severe 缓和 Mild

冷堆前处理与传统前处理效果对比Comparison between Pre-process of Cold Heap and Traditional Pre-processing

对比项目 Contrast project

工艺处理 Production Process

传统前处理Traditional Pre-

processing

冷堆前处理Pre-process of Cold Heap

前处理布面效果Pre-process cloth

cover effection

摩擦较大Large friction毛羽多

rough surface 易产生褶皱

Easy to have fold

光洁、平整、手感较柔软Smooth, flat and soft fabric

染色效果Dyeing effect

/

染敏感色如蓝绿色、啡色、灰色等表现优异

Excellent performance in dyeing sensitive colors

such as, turquoise, brown, grey, etc.

冷堆前处理与传统前处理效果对比Comparison between Pre-process of Cold Heap and Traditional Pre-processing

技术成果 Technological Achievements

• 该技术从 2008 年开始研发， 2009 年正式投产 Started in 2008 and applied in production since 2009

• 目前已在国内多家大型染整企业广泛应用。并在业界获得一致好评及多项国家专利

At present, it is widely used by many large-scale domestic dyeing enterprises and has won consistent acknowledgements with multiple national patents

绳状固色制软后处理设备介绍Introduction of the Post-treatment of Rope Color-fixing Softer Machine

绳状固色制软后处理设备 Post-treatment of Rope Color-fixing Softer Machine

• 为我公司最新研发的染色后处理设备 latest dyeing post-process equipment of Jintian

• 传统工艺中，固色、柔软工序需在染色机内处理，耗时长、能耗大， 不能满足节能环保的新需求，绳状固色机应运而生，节能等方面的优势在 我公司染厂赢得了一致好评 In traditional production, color stabilizing, softening process within the dyeing machine is time and energy consuming. It fails to meet the new

trend of energy saving and environmental protection, thus rope color-fixing softer machine is developed

• 该机通过 6组轧辊、 5组液槽、加料桶定量补充助剂、可在短时间内完成 固色、柔软工序 Can complete color stabilizing and softening process shortly with 6 groups of rolls, 5 groups of liquid tank and refillable additives

• 提高染色机的利用率，缩短了染色全过程的工艺时间，节约能源， 提高生产效率 Improve utilization rate of dyeing machine, shorten the time of dyeing process, reduce energy consumption and enhance productivity

设备优势 Competitive Advantage

-10

10

30

50

70

90

110

130

150

耗水（T） 耗电(kwh）

染色机DyeingMachine

固色制软机Color-fixingSofterMachine

固色制软机与染色机相比

省水 Water Saving 65.1%

省电 Eelectricity Saving 45.0%

Water & Electricity Saving Comparison of Color-fixing Softer Machine and Dyeing Machine

目标 Our Goals

我们将一如既往地开发染整行业的新型技术，同时将这些技术和大家分享。为染整行业的快速发展和环境保护的有效实施尽自己的一份绵薄之力We will continue to develop the latest technology of the dyeing industry while adopting environmental friendly practices throughout our operation

谢谢！Thank you!