What common process problems may be encountered during the production of Polyester DTY?- Hengke Textile Technology Co., Ltd

What common process problems may be encountered during the production of Polyester DTY, and how to effectively solve these problems to improve production efficiency and product quality?

During the production process of Polyester DTY (polyester drawn textured yarn), you may encounter some common process problems. The following are some problems you may encounter and corresponding resolution strategies to improve production efficiency and product quality:

1. Common process problems

Spin breakage: During the spinning process, the fiber suddenly breaks, resulting in reduced production efficiency and unstable product quality.
Rough thread: The surface of the thread is not smooth and rough, which affects the appearance and feel of the fiber.
Poor winding formation: During the winding process, the fibers form poor winding shapes, such as "bird's nest silk", "tangled silk", etc.
Uneven tensile deformation: During the tensile deformation process, the deformation degree of the fiber is uneven, resulting in differences in fiber performance.

2. Solution strategy

Spin break
Check the spinning equipment to ensure that the equipment is operating normally and has no abnormal wear or failure.
Optimize spinning process parameters, such as spinning speed, temperature, pressure, etc., to adapt to the spinning requirements of different fibers.
Strengthen raw material quality control to ensure stable raw material quality and no impurities and oil pollution.
Clean and maintain the spinning nozzle and components regularly to keep them in good working condition.

Threads are rough
Check the wear of spinning nozzles and components, and replace seriously worn parts in time.
Adjust the spinning process parameters, such as spinning speed, temperature, etc., to reduce the roughness on the surface of the filament.
Strengthen raw material quality control to ensure the purity and uniformity of raw materials.
Add an appropriate amount of oil during the spinning process to improve the lubricity and surface quality of the filament.
Poor winding forming
Check the winding equipment to ensure that the equipment is operating normally and has no abnormal vibration or malfunction.
Adjust winding process parameters, such as winding speed, tension, etc., to adapt to the winding requirements of different fibers.
Strengthen the cleaning and maintenance of equipment to ensure the smoothness and cleanliness of equipment surfaces.
Calibrate and inspect the winding device regularly to ensure its accuracy and stability.

Uneven tensile deformation
Check the tensile deformation equipment to ensure that the equipment is operating normally and has no abnormal wear or failure.
Optimize the stretching and deformation process parameters, such as stretching ratio, heating temperature, etc., to adapt to the stretching requirements of different fibers.
Strengthen raw material quality control to ensure the uniformity and consistency of raw materials.
Add an appropriate amount of oil or lubricant during the tensile deformation process to improve the stretchability of the fiber and reduce uneven deformation.

In addition to the above solution strategies, the following measures can also be taken to improve production efficiency and product quality:

Strengthen employee training: Improve employees’ understanding of spinning processes and equipment, and enhance their operational skills and quality awareness.
Introduce advanced technology: Use advanced spinning technology and equipment to improve the level of production automation and intelligence, and reduce the impact of human factors on production efficiency and product quality.
Establish a quality management system: Establish a complete quality management system to monitor and control the entire production process to ensure that product quality meets standards and customer requirements.
Strengthen collaboration with other departments: Strengthen collaboration and communication with production, R&D, purchasing and other departments to jointly solve problems in the production process and improve production efficiency and product quality.