Local Hot Spot: Building "National Textile Model Industrial Cluster" In Changle, Fujian Province

Under the epidemic situation, the global textile industry fell into a downturn, while Changle District, an important textile industry town in Fujian Province, rose against the trend. From January to October this year, the output value of textile enterprises above Designated Size reached 19.603 billion yuan, an increase of 12.4% year on year.

Starting from a mosquito net, Changle Textile Co., Ltd. has made great efforts in the industrial chain and supply chain to realize the great change of industrial cluster of more than 100 billion yuan. Once upon a time, the upstream raw materials and downstream markets of the industry were outside, and they were highly dependent on foreign countries. Through continuous chain reinforcement, chain extension and track expansion, Changle textile has broken through the short board of stable and safe supply chain industrial chain, and has become a "national textile model industrial cluster" and has embarked on a road of value growth.

The problem of breaking through "neck jam" of upstream chain supplement

Compared with the nearly 300 year development history and complete industrial chain of European and American textile industry, Changle textile industry has been facing "pain of caprolactam" since its birth.

"Starting from nylon business, caprolactam, an important raw material, has been stuck for a long time." Chen Jianlong, chairman of Hengshen group, said caprolactam is an important upstream organic chemical raw material for nylon products. Polyamide filament can be obtained by polymerization of caprolactam into chips and then production of chips.

"Caprolactam is monopolized by several international chemical giants, and the companies often ask for high prices but can't buy them. Polymerization chips also need to be purchased from abroad." Chen Jianlong said.

Yongrong Holding Group Executive Vice President Chen Fei also found that caprolactam "in the hands of outsiders.". "As the bargaining power and the decision-making power of sales quota are in the hands of the seller, the cost of raw materials of Changle textile enterprises is controlled by others, which limits the capacity expansion. There have even been restrictions on sales by the other party, and we have made a meal without rice."

The important links of the industrial chain have been "stuck", leading enterprises Hengshen group and Yongrong holdings began to lay out the 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 manufacture of caprolactam. It started production three years later, relieving the supply pressure. In 2017, Hengshen group spent 1 billion yuan to purchase the technology license of 400000 tons of caprolactam. After the acquisition of all shares of Forrest Holland caprolactam plant in 2018, Hengshen group has become the largest caprolactam production group in the world, with an annual production capacity of about 1.5 million tons, which can meet the demand of domestic market, and some of which are exported and exported.

Chen Jianlong said that in 2010, China's caprolactam production capacity only accounted for about 10% of the global production capacity. After solving the "neck sticking" problem, the domestic caprolactam annual production capacity increased to 5.16 million tons, accounting for about 58% of the global production capacity. Caprolactam price also dropped from more than 20000 yuan / ton in 2010 to 15000 yuan / ton at present.

Changle textile industry has broken through the bottleneck of caprolactam raw material supply and opened up the whole industrial chain of "aromatic hydrocarbon caprolactam polymerization nylon fiber" through acquisition and business invitation. At present, Changle textile enterprises have a voice in the global caprolactam market.

Technological process of midstream strong chain innovation mode

Textile industry is a labor-intensive industry, the industry generally reflects that the number of labor can not keep up with the speed of capacity expansion, and labor shortage is prominent. In order to solve this problem, Changle textile industry, driven by innovation, has gradually realized automation, intellectualization and digitization by improving efficiency through "machine replacement" mode, consolidating quality with intelligent production technology, and enabling the middle reaches of the industrial chain by means of industrial Internet.

Entering the automatic production workshop of Jingfeng technology, 65000 silk cakes are produced from more than 1000 spinning positions every day. After the automation transformation, only 1 / 3 employees need to be retained in the whole process of feeding, weaving, transportation, packaging and warehousing. Zheng Yongguang, chairman of Changyuan Textile Co., Ltd., said that after the opening of unmanned workshops, the number of workers in workshops has been reduced from 120 to 12.

"Machine replacement" provides a new driving force for the industry to increase efficiency and speed: the spinning equipment runs automatically at the production speed of 5000 meters per minute, and the yarn length is 300 kilometers per hour; The semi-finished products are automatically transported on the production track and accurately connected; Industrial camera instead of naked eye inspection products for broken wire, oil contamination; The robot equipped with the finished product is equipped with radar system, intelligent positioning, and the falling time is shortened from 60 seconds to 30 seconds; The storage capacity of intelligent warehouse is 14 times that of ordinary warehouse with the same building area

Chen Fei said that through the research and development of automatic and intelligent production lines, the company not only improved efficiency and production capacity, but also improved product quality: saving labor and land costs by 60% to 70%, reducing production costs by 500 yuan / ton - 800 yuan / ton, and increasing the product quality excellence rate by 3%.

"The textile industry has a strong periodicity, and it takes a certain time to receive orders, produce, inspect, package, store in and deliver these links. Therefore, the materials to be ordered in peak season should be prepared in advance." Jin Lun high fiber chairman Zheng Baoyou said. In order to ensure the stable and orderly operation of the supply chain and industrial chain, Changle textile enterprises explore to open up all links in the production and sales chain. "The industrial Internet enables independent links to access the system, providing important decision-making information for the company's sales, research and development, production and other business activities." In the workshop of Jinlun high-speed fiber, the reporter saw that the "brain" in the main control room of the workshop was managing and controlling the whole production process. On the screen, information such as user demand, order quantity, warehouse vacancy, shipment situation and future order anticipation was displayed. Zheng Han, general manager of Jinlun high-speed fiber, said that the company is building a product development, production and sales system closer to the market.

Downstream chain extension, track development and added value

Warp knitting is an important link connecting the upstream chemical industry, chemical fiber, spinning, end dyeing and finishing, clothing in the textile industry chain. However, it has been faced with the development difficulties such as low added value in the value chain and dependence on import of supporting warp knitting machines. In the process of more than 30 years of cultivation, Changle has continuously strengthened the strength and strength of the industrial chain. By expanding the machine track and enhancing the ability of independent design, the textile industry system and industrial chain are completely independent, and the "world warp knitting is in China, and China's warp knitting is in Changle".

China's textile warp knitting machinery has a large demand, but its market share was once occupied by German Karl Mayer, which once monopolized the high-end warp knitting machine market in China. Zheng Chunle, who started his family run HANGGANG textile company, said that the dependence of warp knitting machines on imports has brought many problems, such as high procurement costs, long delivery time, and difficult after-sales maintenance and operation of machinery.

"In 2000, the company spent more than 700000 yuan to purchase two sets of second-hand German equipment, but the machine did not work after it was bought back. The Chinese workers were at a loss and asked German experts to repair it. The cost was too high to bear." Zheng Chunle initiated the idea of expanding the track and producing domestic warp knitting machines, breaking through the international monopoly.

Fujian Xingang Textile Machinery Co., Ltd. was born. Zheng Chunle, general manager, said that the beginning of the road from "copy homework" began. The company invests tens of millions of yuan in R & D every year, more than 10% of its revenue, to study the latest mechanical structure and equipment of warp knitting machines in the world. After four years of persistence, the company independently designed and produced the first lace machine.

"At present, the company's multi bar high-speed jacquard warp knitting machine has a speed of more than 660 rpm." Zheng Chunle said that at the same time, the price of Xingang textile machine with the same speed is half cheaper than that of German brand machine. The "counter attack" of Xingang textile machinery reduced the industry cost and promoted the prosperity of Changle warp knitting lace industry.

After the self-designed and produced warp knitting machines have solved the problem of "neck sticking" in the downstream of Changle textile industry, warp knitting enterprises have gradually shifted from independent processing to independent design to improve the added value of products.

In terms of innovative new fabrics, the anti cutting nylon fiber developed by Yongrong Jinjiang has the functions of antibacterial, sweat absorption, scratch resistance and skin affinity, which can be made into high-performance protective gloves and garments. Changyuan textile and Donghua University, Minjiang University, China Academy of Textile Sciences and other universities, scientific research institutes to carry out industry university research cooperation, developed antibacterial, moisture absorption and other textile yarn to meet the needs of anti epidemic, applied in the field of anti epidemic textiles production. At present, Changle has more than 1300 affiliated enterprises in the field of functional fiber alone, with a total output value of over 200 billion yuan. It has built a complete industrial chain of functional fiber manufacturing including chemical fiber raw materials, cotton spinning and warp knitting.