Changle, Fujian Province has built a “National Textile Model Industrial Cluster”
The global textile industry has fallen into a downturn due to the epidemic, but Changle District, Fuzhou, Fujian Province, an important town in the domestic textile industry, has bucked the trend and is rising. From January to October this year, the output value of textile enterprises above designated size was 196.603 billion yuan, a year-on-year increase of 12.4%.
Starting from a piece of mosquito net silk, Changle Textile has grown from scratch, from weak to strong, and has worked hard on the industrial chain and supply chain to achieve an industrial cluster super A huge change worth hundreds of billions. In the past, the industry’s upstream raw materials and downstream markets were both outside, and it was highly dependent on foreign countries. By continuously strengthening and extending the chain and expanding the track, Changle Textile has broken through the shortcomings in the stability and safety of the supply chain and industrial chain, becoming a “national textile model industrial cluster” and embarking on a path of value growth.
Upstream chain replenishment breaks through the “stuck neck” problem
Compared with the nearly three hundred years of development and complete industrial chain of the European and American textile industries, Changle’s textile industry has faced the “pain of caprolactam” since its birth.
“The company started from the nylon business, and the important raw material caprolactam has been ‘stuck’ for a long time.” Chen Jianlong, chairman of Hengshen Group, said that caprolactam is an important part of nylon products. of upstream organic chemical raw materials. Caprolactam is polymerized into slices, and the slices are then produced to obtain nylon yarn.
“Caprolactam is monopolized by several international chemical giants, and companies often ask for it at high prices but are unable to buy it. Polymer chips also have to be purchased from abroad.” Chen Jianlong said.
Chen Fei, executive vice president of Yongrong Holding Group, also discovered that caprolactam was “in the hands of outsiders.” “Since the bargaining power and sales quota decision-making power rest with the seller, the raw material costs of Changle Textile Enterprises are controlled by others, which limits the expansion of production capacity. There have even been sales restrictions by the other party, and we have a situation of ‘making rice without rice’.”
Important links in the industrial chain have been “stuck”, and leading enterprises Hengshen Group and Yongrong Holdings have begun to deploy upstream of the industrial chain to make up for the weak links. In 2014, Yongrong Group cooperated with Fujian Investment and Development Group to set up a factory in Xiuyu, Putian, to study the manufacturing of caprolactam, and started production three years later, alleviating supply pressure. In 2017, Hengshen Group spent 1 billion yuan to purchase a technology license for 400,000 tons of caprolactam. After acquiring all the shares of Fubant’s Dutch caprolactam factory in 2018, Hengshen Group has become the largest caprolactam production group in the world, with an annual production capacity of approximately 1.5 million tons, which can meet the domestic market demand, and someExportExport sales.
Chen Jianlong said that in 2010, China’s caprolactam production capacity only accounted for about 10% of global production capacity. After solving the “stuck neck” problem, domestic annual caprolactam production capacity increased to the current 5.16 million tons, accounting for about 58% of global production capacity. The price of caprolactam has also dropped from more than 20,000 yuan/ton in 2010 to the current 15,000 yuan/ton.
By extending the industrial chain through acquisitions and business promotion, Changle Textile Industry has broken the supply bottleneck of caprolactam raw materials and opened up the entire industrial chain of “aromatic hydrocarbons-caprolactam-polymerization-nylon fiber”. At present, Changle Textile Enterprises has a say in the global caprolactam market.
Midstream strong chain innovation model technical process
The textile industry is a labor-intensive industry. The industry generally reflects that the number of laborers cannot keep up with the speed of production capacity expansion, and labor shortages are prominent. In order to solve this problem, Changle Textile Industry is driven by innovation and improves efficiency through the “Machine Substitution” model, improves quality with intelligent production technology, and empowers the midstream of the industrial chain through industrial Internet means links, gradually realizing automation, intelligent, and digitization.
Walking into the automated production workshop of Jingfeng Technology, 65,000 silk cakes are produced from more than 1,000 spinning positions every day. After the automation transformation, only 1/3 of the employees will be retained in the entire process of feeding, weaving, transportation, packaging, and warehousing. Zheng Yongguang, chairman of Changyuan Textile Co., Ltd., said by comparison that after the unmanned workshop was launched, the number of workers in the workshop was reduced from 120 per workshop to 12 per workshop.
“Machine substitution” provides new momentum for the industry to improve efficiency and speed: spinning equipment operates automatically at a production speed of 5,000 meters per minute, producing 300 kilometers of yarn in one hour; semi-finished products are automatically transported on the production track. Accurate docking; industrial cameras replace the naked eye to inspect products for broken wires and oil stains; the doffing robot equipped with finished products is equipped with a radar system and intelligent positioning, and the doffing time is shortened from the original 60 seconds to 30 seconds; the storage capacity of the smart warehouse reaches the same building area 14 times that of an ordinary warehouse…
Chen Fei said that by developing automated and intelligent production lines, the company has not only improved efficiency and production capacity, but also improved product quality: saving 60 to 70% of labor and land costs. , reducing production costs by 500 yuan/ton to 800 yuan/ton, and improving product quality by 3%.
“The textile industry is highly cyclical, and it takes a certain amount of time to receive orders, produce, inspect, pack, store in, and deliver. Therefore, materials for peak season orders must be prepared in advance.” said Zheng Baoyou, chairman of Jinlun High Fiber. In order to ensure the stable and orderly operation of the supply chain and industrial chain, Changle Textile Enterprises explores opening up all links in the production and sales chain. “Industrial InternetThe network allows independent links to access the system, providing important decision-making information for the company’s sales, R&D, production and other business activities. “In Jinlun High Fiber’s workshop, the reporter saw that the “brain” in the main control room of the workshop was managing and controlling the entire production process. The screen displayed information such as user demand, order quantity, warehouse vacancies, shipment status and future order predictions. Zheng Han, general manager of Jinlun High Fiber, said that the company is building a product development, production and sales system that is closer to the market.
Downstream extension chain expansion track to increase added value
Warp knitting is an important link connecting the upstream chemical industry, chemical fiber, spinning and end dyeing and finishing of the textile industry chain, and clothing. However, it has always faced the problem of adding value in the value chain. It is relatively low and the industry relies on imports of supporting warp knitting machines and other development difficulties. In the process of more than 30 years of cultivation, Changle has continuously strengthened the industrial chain. By expanding the machine track and enhancing independent design capabilities, it has ensured the integrity and independence of the textile industry system and industrial chain, and has successfully realized the “world warp knitting in China, China’s economic Edited in Changle”.
my country’s textile warp knitting machinery has a large demand for quantity, but the market share was once occupied by Germany’s Karl Mayer, which once monopolized my country’s high-end warp knitting machine market. Zheng Chunle, who started his family’s business in Hanggang Textile Company, said that the company’s reliance on imported warp knitting machines has brought many problems such as high procurement costs, long delivery times, and difficulty in after-sales maintenance of machinery.
“In 2000, the company spent more than 700,000 yuan to purchase two sets of second-hand German equipment, but the machines failed to operate after they were bought back. The Chinese workers were helpless and asked German experts to repair them. The cost was too high and unbearable.” Zheng Chunle came up with the idea of expanding the competition. Dao, the idea of producing domestic warp knitting machines and breaking the international monopoly.
Fujian Xingang Textile Machinery Co., Ltd. was born. General Manager Zheng Chunle said that the journey started with “copying homework”. The company invests tens of millions of yuan in research and development every year, more than 10% of its revenue, to study the latest mechanical structures and equipment of warp knitting machines in the world. After four years of persistence, it independently designed and produced the first lace machine.
“The current multi-bar high-speed jacquard warp knitting machine produced by the company has a speed of more than 660 rpm.” Zheng Chunle said that at the same time, the price of Xingang Textile Machinery for warp knitting machines with the same speed is half cheaper than that of German brand machines. . Xingang Textile Machinery’s “counterattack” has reduced industry costs and promoted the prosperity of Changle’s warp knitting lace industry.
After the independently designed and produced warp knitting machines solved the “stuck neck” problem in the downstream of Changle’s textile industry, warp knitting companies gradually shifted from independent processing to independent design to increase the added value of products.
In terms of innovative new fabrics, the cut-resistant nylon fiber developed by Yongrong Jinjiang has antibacterial, sweat-absorbent, anti-scratch and skin-friendly functions, and can be made into high-performance protective gloves and garments. Changyuan Textile has carried out industry-university-research cooperation with universities and scientific research institutes such as Donghua University, Minjiang University, and China Academy of Textile Sciences to develop antibacterial, moisture-absorbent and other textile yarns that meet anti-epidemic needs and are used in the production of anti-epidemic textiles. At present, Changle has more than 1,300 related companies in the field of functional fibers alone, with a total output value exceeding 200 billion yuan, creating a complete industrial chain of functional fiber manufacturing including chemical fiber raw materials, cotton spinning, and warp knitting.
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