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In order to explore how the new quality productivity develops in the textile industry, the reporter came to the textile town with a thousand-year history: Shengze. Walking on the streets of the town, the reporter's biggest feeling is that everything is "renewed". Facing the spring breeze, many enterprises are busy changing equipment and building factories.
Visit the textile town: facing the spring breeze, everything is "renewed"!
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"Who cut a silk painting of Wujiang, skillfully tailoring a gorgeous robe", is talking about Sheng Ze's Song Jin. In a Song Jin textile factory, the reporter saw that the old machine had not had time to be moved, and the new equipment was already at full power. The newly purchased machine has 20,000 stitches and can weave more than 800 continuous and complete patterns on a one-meter-four long brocade, which was not possible with the previous equipment. And to support such a difficult work, it is the 40,000 bearings in the machine, which are also full of "Chinese style".
Wu Jianhua, the person in charge of the enterprise, told reporters that with these new domestic machines, it is not only cost-effective and high-quality, but also has a tenfold increase in production capacity compared with before. Because of consumers' love for traditional culture, the orders for the whole year have been full in March.
Spinning machines should be "upstairs", and traditional industries should also be "on the next level"!
At present, there are more than 100 enterprises in Shengze Town that are undergoing transformation and upgrading. Walking into a new factory that looks like an office building, we find that its internal structure is very different from that of an ordinary textile factory. In order to improve the utilization of space, most of the newly built factories are three-dimensional, and the spinning machines will collectively "go upstairs" when the raw materials are placed on the first floor. In order to adapt to this "vertical production" model, the factory covers every spinning link from the first floor to the top floor with smart equipment. The raw materials are automatically "blown upstairs" from hundreds of pipes on the first floor, and then go through a series of links such as carding, drawing, and vortex spinning, and then to the final sorting and warehousing, the whole process is completely free of manual intervention, and the production efficiency is 10 times higher than the traditional spinning mode, and the cost is also reduced by 15%.
Once one person used one machine, now one person can "see" six. The intelligent transformation is also reflected in many small details. Yarn breakage used to be the biggest headache in textile mills. Manual knotting is not only inefficient, but also affects the quality of the fabric. Now, the new device with an intelligent identification system can accurately identify broken yarns and then automatically join them with a robotic arm.
At present, all 134 intelligent devices in the entire workshop are connected to the big data platform, and the output of the equipment, the efficiency of operation, and all the data can be clearly presented on the large screen in the office. Wu Xingwu, the person in charge of the company, said that the financial pressure on equipment renovation is relatively large, so they have been very hesitant to build this plant. However, after the transformation of the factory, the production capacity has gone up and the cost has come down, and these tangible effects have strengthened their confidence. The next upgrade project they are going to talk about will be larger than the current factory.
"Two bedrooms and one living room": a new model of green trade
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"High energy consumption, not environmentally friendly", many people will have such a stereotype of the textile industry. In this textile town survey, we also found that today's textile industry is moving green. In the Oriental Silk Market in Shengze Town, there are more than 1,600 import and export enterprises. The reporter observed that many companies not only have a showroom like a "fabric supermarket", but also a design room and a laboratory.
In this way, the "two-bedroom and one-living room" model has become the standard configuration of many enterprises. Now, after the fabric order is produced, it is not rushed to ship, but sent to the laboratory as soon as possible. Jiang Nana, the person in charge of a foreign trade enterprise, told reporters that they will spend at least two days to send the finished cloth to a professional environmental protection testing agency after getting the printed and dyed fabrics, and before that, they will test it in their own laboratories to predict the risk for customers in advance.
There are many more fabrics with green "genes" from the laboratory to "go to sea to see the world". Not long ago, Jiang Nana's company cooperated with colleges and universities to develop a green "iterative polyester". The material saves up to 50 percent and 80 percent of energy in the production process, as well as a 30 percent reduction in the use of dyeing and post-processing aids. It is this "green guarantee" that has allowed them to receive orders for 13 million meters of fabrics in the first two months of this year.
More green actions are also taking place in small towns.
In a printing and dyeing company, the reporter saw that the traditional dyeing vat was replaced by "digital printing". Patterns and patterns are printed on paper, and then combined with fabrics through sublimation, omitting all the links of water. In order to further green upgrading, the company has also closed many oil-based ink printing production lines and expanded the scale of water-based ink printing. Zhao Quan, the quality control manager of the enterprise, said that the difference between water-based ink and oil-based ink is that the content of harmful ingredients to the human body is relatively reduced by 50 to 60%, and it is transforming and upgrading in a greener direction, which is what many companies in their industry are doing.
Just a few days ago, the Wujiang Textile Circular Economy Industrial Park project started, covering 6 projects in the fields of green environmental protection, high-end printing and dyeing. Improving the content of science and technology, reducing pollution emissions, and accelerating the sustainable development of low-carbon recycling are becoming a new vane for the textile industry chain.
"Breathing" innovation "factors"
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Now Shengze Town, there are more than 1 national high-tech enterprise and 3 national science and technology small and medium-sized enterprises per square kilometer. In 2023, the R&D investment of industrial enterprises above designated size in small towns will be 2.043 billion yuan, a year-on-year increase of 12.5%.
The "concentration" of science and technology in textile towns is getting higher and higher.
During the morning rush hour, there are six or seven scientific research staff in a siu mai shop in the town with a store area of less than 30 square meters. I talked to one of them, most of whom are from the nearby National Innovation Center for Advanced Functional Fibers, with an average age of only 30 years old.
Walking into this innovation center with young researchers is more like stepping into the future. The carbon dioxide in industrial exhaust gases is captured, purified, liquefied, and transformed into breathable "carbon-negative" fibers. To make a carbon-negative garment, the amount of carbon dioxide used is equivalent to the amount of carbon dioxide captured by a tree in a year. Not long ago, the research team has just developed a new needle-free electrospinning system. R&D engineer Wang Hengyu said that this is the result of more than 300 repeated trial and error, and it has also broken the monopoly of foreign countries.
The high-end "face" is the "lining" of innovation
Five kilometers away from the Innovation Center, one of the world's largest industrial yarn smart factories has just been completed and put into operation, accounting for about one-third of global output. It is also the only factory in the world that can directly produce ultra-coarse industrial yarn above 8,000 denier and ultra-fine industrial yarn below 7 denier.
Tang Fangming, the person in charge of the enterprise, told reporters that the industrial yarn they produce will generally be used in many high-end industries and national instruments, such as civil engineering, marine engineering, oil and gas transportation and intelligent equipment. And the thickest and thinnest filament actually integrates a lot of innovative technologies of the company, this kilogram of the thinnest fiber, its monofilament can go around the earth.
The pace of innovation is accelerating, and the composition of people in factories is changing. At present, in addition to the technical positions of textile professionals, many new positions such as information technology, software engineering, artificial intelligence and data analysis have been added in the enterprise. Tang Fangming said that at present, the talent structure of enterprises is undergoing deep changes, and it also promotes the textile industry cluster to achieve a high degree of integration of innovation chain and industrial chain, which will attract talents in this area to join the cluster and achieve higher quality development of the cluster.
Data Insights: A New "Layout" of Data Talking
This may be the textile industry you know: it is one of the three pillar industries of consumer goods in the mainland, and in 2023, the output of garment enterprises above designated size in the mainland will be 19.39 billion pieces; China is also the world's largest textile country, with the total fiber processing of the textile industry accounting for more than 50% of the world's total, and the growth rate of the world's total textile and garment exports is also more than 50%. One out of every 5 sweaters in the world is from Dalang, Guangdong, one out of every 4 swimsuits is from Huludao, Liaoning, and one out of every 3 pairs of socks is made in Zhuji, Zhejiang.
This may be something you don't know about the textile industry: in China, everything can be "woven", even seaweed. At present, a seaweed fiber production line for textile and garment with the world's largest production capacity has just been put into operation, and a "sea cotton warehouse" with a capacity of up to 5,000 tons is being established. Waste clothing, leftovers, and plastic bottles can be turned into "silk" after recycling. The polyester silk extracted from 8 waste plastic bottles can be woven into a men's T-shirt. There is also the power of textiles in the great vessels of the country. In the construction of the Hong Kong-Zhuhai-Macao Bridge undersea tunnel, about 6,000 tons of reinforced concrete joints need to be hoisted into the seabed to a depth of 28 meters, and the lifting belt is made of anti-creep industrial yarn, and the resin-based carbon fiber material is light in weight and rigid, and is used in the fuselage of the C919 large aircraft.
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This is today's Chinese textile industry: the ability to innovate is constantly strengthened. The production capacity of high-performance fibers accounts for more than one-third of the world's total, and the autonomy rate of textile machinery exceeds 75%. In 2023, 402 textile enterprises will be recognized as "specialized, special and new" small giant enterprises and individual champion enterprises.
Green and sustainable development. In 2023, the output of recycled chemical fibers will exceed 5 million tons, and a green and low-carbon industrial system with a full life cycle will be initially established.
As of September 2023, the digitization rate of production equipment and the networking rate of digital equipment of textile enterprises have reached 56.5% and 49.3% respectively, which are higher than the national manufacturing average.
Director丨Shen Yong, Yan Shuainan, Zhang Qin
Producer丨Wang Yan Liu Ruoyao
Producer丨Yue Qun, Ding Yani, Nian Jia, Zhu Yinran
Reporter丨Yang Yaoyu, Xu Jing, Yang Guang, Huang Guanhua, Wang Xiaofan, Zhu Zhenhai, Qingdao Station
Editor丨Sun Tao, Jiang Jiajia, Zhou Xueying
New Media丨Yang Xiaobo, Zhang Hao, Wang Weijie, Hao Tian
Editor in charge: Liu Bo