Keqiao Blue Printing Fashion Town: "Dye Vat" Butterfly Transformation And Breeding New Machine

Along Hangzhou Bay Avenue, you will come to the blue print fashion town of Keqiao Economic and Technological Development Zone. Along the way, a car full of white cloth or printing and dyeing cloth shuttle back and forth. On the electronic screens at the gate of many printing and dyeing factories, job recruitment notices are playing in a rolling manner, and rows of private cars are crowding the gate of the factory.

In Zhejiang Dongsheng printing and dyeing Co., Ltd., Zhang Yufeng, executive deputy general manager, received the reporters and his party. When asked about the market situation this year, he said with a smile: "it has completely walked out of the impact of the epidemic and returned to the level of the same period in 2019. The competition among enterprises is very fierce with respect to design, pattern and service. But in any case, it is not wrong to take the green high-end road. "

Zhang Yufeng's words showed a clear understanding of the development path of printing and dyeing industry. Taking the development road of "green high-end, world leading" has become the consensus of blue print fashion town enterprises.

Gathering migration to welcome new students

On May 10, the weather was hot, and the Guozhou printing and dyeing group project, which was relocated from three printing and dyeing enterprises, is under construction. At present, the main body of the 5-storey factory building has risen from the ground, and the interior decoration is carried out in an orderly manner.

"The total investment of the project is 700 million yuan, and the goal is to build an international leading intelligent printing and dyeing factory." Yang Jie, the project leader, is full of expectations for the future.

On the morning of December 28, 2019, the national week printing and dyeing group project started, which is the first construction project to promote the cross regional agglomeration of urban printing and dyeing industry. For the "migration" from Yuecheng district to Keqiao blue print fashion Town, Yang Jie said it was a new life.

"After decades of printing and dyeing, the enterprise has been able to survive before, but now it is determined to take advantage of the situation to upgrade and create a new situation." Yang Jie said that the new Guozhou group project eliminated all the original equipment and replaced it with advanced equipment from Germany, Japan and Italy. After the completion of the project, the annual production capacity of 5000 tons of loose fiber, 22000 tons of yarn and 400 million meters of printing and dyeing cloth will be formed, with an annual sales revenue of 1.6 billion yuan and profits and taxes of 300 million yuan.

At present, there are 108 printing and dyeing enterprises in Binhai Industrial Park. Over the past 10 years, 212 printing and dyeing enterprises scattered all over the country have "migrated" to this place after experiencing the "pains" of integration and upgrading.

In 2012, Zhejiang Dongsheng printing and dyeing Co., Ltd. was the first to move to the gathering area. Zhang Yufeng still remembers his first "crab eating" act“ At the beginning, a lot of worries were pressing on my mind. " First of all, he was worried about the increase in costs, the elimination of all equipment in old factories, and the investment of hundreds of millions of yuan in the construction of new factories, just like "cutting meat"; Secondly, customers and employees move from the "golden section" beside jinkeqiao avenue to Qiantang River, one hour's drive from the city. Would they like to follow? This was a problem that almost all relocated enterprises had to face at that time.

"Relocation and gathering force us to advance to the middle and high end." Zhang Yufeng said that because of the rising costs, the original polyester series of four side bombs, weft bombs and other low-end products, basically no profit margin. After putting into production again in 2014, the company decisively tried to develop knitting and woven series of new products. In the second year, it obtained considerable returns: not only did the profit margin double, but also became the first enterprise with tax revenue of more than 30 million yuan in blue printing fashion town. In addition, the enterprise also adhered to the road of green development, and was rated as one of the first batch of Shaoxing dyeing and printing industry green benchmark demonstration enterprises, and was awarded with pollution discharge index.

Agglomeration effect, accumulation and development. Taking blue printing fashion town as a representative, in recent five years, Keqiao has eliminated 3.816 billion meters of backward printing and dyeing capacity, invested more than 1.5 billion yuan in environmental protection equipment, increased the proportion of international advanced green equipment application from 30% to more than 60%, and the comprehensive energy consumption of industrial added value above designated size decreased by 8.1% year-on-year, and the added value per meter of printing and dyeing cloth increased by more than 15%, and the industrial quality and efficiency were improved significantly.

A new way of whole chain innovation

In Zhejiang Baofang printing and dyeing Co., Ltd., the gray cloth at the gate of the factory is stacked neatly, which looks like hills from a distance, full of momentum“ Can such a large amount of grey cloth cause overstock of products Facing the reporter's question, Qi Xin, executive director of the company, laughed, "it's quickly used up. Our daily production capacity is 1.4 million meters, which can be converted into kilometers from Keqiao to Beijing."

Baofang printing and dyeing is an integrated industry and trade enterprise specializing in African market. Its batik printing cloth is well-known in Africa and is the largest supplier of local market share. Its sales volume reached 180 million US dollars last year. Not only that, from 2016 to 2019, the company's sales achieved an average annual growth of about 30%.

The rapid growth of sales benefited from an important innovation of Baofang printing and dyeing: research and development of imitation batik calico to replace real batik calico. Rosin is used in the production of true batik printing cloth, which will cause pollution. Under the increasing pressure of environmental protection, the profit space of this cloth is gradually reduced. In 2014, through independent research and development, Baofang printing and dyeing Co., Ltd. produced batik printing cloth which was similar to the real batik in color and feel, and produced more environmentally friendly imitation batik printing cloth.

"In order to match the new process, we changed almost all the production lines." Qi Xin told reporters that the new product not only reduced the production cost by half, but also won a larger market with the price advantage, but also reduced the unit energy consumption by about 60% due to the improvement of technology and equipment.

Innovation is not a master, it needs courage and courage. In January this year, Zhejiang Yingfeng Technology Co., Ltd. was listed on the A-share main board, becoming the first pure printing and dyeing listed enterprise in China in 15 years.

After reading the information disclosed by the company, the reporter saw that the printing and dyeing "leader" is striving for innovation and research: from 2016 to 2018, the R & D investment reached more than 100 million yuan. Its key research and innovation areas are mainly concentrated in high-quality textile dyeing and finishing technology, energy-saving and emission reduction dyeing and finishing technology and printing and dyeing intelligent manufacturing technology. It has 53 patents, 18 independent R & D technologies and 5 imported technologies have been put into production after digestion.

"Industrial agglomeration is the first step, followed by innovation breakthrough, and innovation consciousness has been deeply embedded in the soul of most enterprises." According to the relevant person in charge of Keqiao Economic and Technological Development Zone, in the past three years, the proportion of R & D expenses of Keqiao printing and dyeing industry in operating revenue has increased from 2.9% to 4.3%, which is behind the investment of real gold and silver.

The whole chain innovation also makes "Keqiao manufacturing" label fashionable. Zhejiang red, green and blue textile printing and dyeing Co., Ltd., which introduces more than 20 new patterns every day, has won the "Fashion Color Award" in the China fashion fabric design competition; A number of enterprises, represented by Yongli printing and dyeing, BINKANG printing and dyeing, Xinshu textile, etc., have successfully entered the fabric supplier team of international famous brands such as Gucci, coach and Zara; In the 9th Keqiao Fashion Week held not long ago, designer Liu Wei of the Golden Summit Award carried the green environmental protection fabrics of Zhejiang Huachen printing and dyeing Co., Ltd., a local enterprise of Keqiao, onto the opening show

The innovation "spray" of printing and dyeing enterprises has become the surging power of high-quality development of the whole industry. The reporter saw in the exhibition hall of blue print fashion Town: flexible manufacturing system, automatic sizing system, dyeing and chemical material automatic conveying system, etc., which represent the advanced technology, the reclaimed water reuse technology of biological membrane treatment, the waste heat recovery and utilization technology of high temperature waste water, etc., which represent the cutting-edge products, such as superfine fiber synthetic materials and industrial special fabrics, Highlight the content of science and technology, leading the industry fashion.

Shu Zhi takes the lead and makes further efforts

In the face of the digital wave, the blue printing fashion town on the road of industrial transformation and upgrading is accelerating towards the direction of "printing and dyeing brain" and "unmanned factory".

In Zhejiang Yuexin printing and dyeing Co., Ltd. newly built industrial Internet "cockpit", the reporter saw the embryonic form of "digital twin factory". The whole wall is divided into several electronic display screens, and the production modules are arranged in a dense manner: Production Scheduling Kanban, production and operation center, production progress intelligent tracking screen, quality dynamic processing center, cylinder process monitoring, molding machine intelligent monitoring... According to Pu Jianfeng, chairman of the company, they have moved a branch plant of pilot digital transformation into "cloud", Through the "cockpit" large screen or mobile app, managers can master every dynamic of the workshop in real time.

"Going to the cloud" is only the basis of digital transformation, and the ultimate goal is to borrow big data to promote enterprise cost reduction and efficiency increase and achieve lean management“ For example, what kind of scheduling scheme can make the production equipment utilization rate reach the highest? What are the causes of product quality problems? Whether the existing dyeing formula can be improved... These are the problems we need to overcome in the next step. " Pu Jianfeng said.

Although facing many challenges, Pu Jianfeng is full of confidence. In less than a year of transformation, "Yuexin printing and dyeing" has tasted the sweetness of Digitization: from January to April this year, the sales volume of the enterprise increased by about 30%, but the cost decreased by 5% - 10%.

In the interview, the reporter found that almost every enterprise talks about "digitalization", and many have put it into practice“ It is obvious whether we should take advantage of this transformation to "set sail again" or hesitate to be gradually eliminated by the industry. " Li Chuanhai, chairman of Shaoxing Haitong printing and dyeing Co., Ltd., said that for printing and dyeing enterprises, digitization is not only the upgrading of equipment, but also a complete reform of enterprise production management, and a new step from extensive management to lean management.

Wang Jiang, who has more than 20 years of experience in big data and cloud computing and served as a senior engineer of Google headquarters, has moved the whole team from Beijing to Keqiao. At present, "number system technology" established by Wang Jiang has reached deep cooperation with 10 Keqiao local printing and dyeing enterprises, such as "Yuexin printing and dyeing" and "English printing and dyeing", to jointly develop the Internet platform for printing and dyeing industry.

In addition to "singing opera" by enterprises, it is also necessary for the government to "set up a stage".

This year, Zhejiang has formulated the "Zhejiang Province digital economy system construction plan", which plans to take "industrial brain + future factory" as the core structure and select about two advantageous industries to promote the construction of industrial brain version 1.0. Keqiao, who has been playing a leading role in reform, is actively planning to build the brain of printing and dyeing industry.

"The specific plan is still under revision, but it can be roughly divided into two parts: the government side and the enterprise side. The government side is to share and apply the data of public resources of various departments, so as to provide help for the government to grasp the industrial development trend and predict the industrial development trend; The enterprise side is to build a public platform for the whole industry chain, with the data supply chain as the link to promote the reconstruction of production mode and business model Keqiao District Economic and Information Bureau digital development center director Qiu Bo said.

In the view of Fu Shuangli, chairman of Yingfeng technology, the future Internet platform of printing and dyeing industry should be like Taobao and meituan. Enterprises entering the platform become businesses. Customers can directly judge and compare on the platform and choose who should be given this list“ This will completely change and subvert the whole printing and dyeing industry. " Fu Shuangli said.

"Dye vat" butterfly change new machine. This green, innovative and intelligent printing and dyeing town is making full efforts to the new blue sea.