In 2007, the Yihua Filament Center faced intense competition from conventional products. With an investment of 180,000 yuan, they successfully transformed their production line to produce high-value POY fine denier porous filaments, significantly boosting annual gross profit by nearly 2.5 million yuan. This was just one example of the center's broader strategy over the past two years—carrying out extensive technological upgrades and transformations to enhance device capabilities, improve product quality, and unlock new efficiency potential.
The domestic filament market is currently oversupplied, with many advanced private enterprises having modern production lines built after 2004. These lines are technologically superior, capable of producing high-value-added products efficiently and consistently. In contrast, the Filament Center’s final production line had been in operation since before 2001. To close the gap, the center developed a comprehensive innovation plan, assigned responsible departments, and focused on key technological breakthroughs to introduce new products and increase value.
One major initiative involved the FDY52 line, which previously only produced conventional FDY and was a major source of losses. After market research, the center decided to retrofit this line to produce higher-value products, improving both production capacity and competitiveness. They later applied similar innovations to the FDY53 and FDY54 lines, implementing dual-spinning technology to produce fine denier FDY. This led to a profit increase of around 300 yuan per ton, helping to mitigate seasonal price fluctuations and reduce operational risks.
Another key area of development was the introduction of high-end products for export. A joint venture in Zhejiang required strict raw material standards, and even cheaper options were rejected if they didn’t meet specifications. To meet these demands, the center began R&D on FDY55 and FDY56 lines, focusing on process optimization such as temperature control and draw ratio adjustments. This allowed them to produce a highly sought-after felt material that exceeded the performance of local private enterprises, leading to increased orders and customer satisfaction.
Quality improvement became another focus of innovation. The center realized that even minor defects could lead to customer complaints, so they prioritized long-term quality improvements. For instance, they addressed issues with black and yellow paste components by redesigning filters and modifying distribution boards, reducing the defect rate from 35-40% to zero. On FDY60 and FDY61 lines, they extended component connection blocks to meet the quality demands of KDY products. Additionally, after introducing fine denier FDY, they improved winding parameters and paper tube quality, ultimately eliminating all user complaints by the end of 2007.
Energy conservation and emission reduction also became a priority. The company set energy-saving targets of 3-5% for the Filament Center in 2007 and 2008. The center implemented various technical solutions, including new technologies, processes, and materials, resulting in a 3.11% decrease in energy consumption compared to the previous year. One notable project involved replacing chilled water with circulating water from the power plant. By using a new pressured open-hole technique, engineers successfully connected the two systems without interrupting operations. This allowed the chiller to be completely shut down during winter, saving nearly 370,000 yuan annually at a cost less than half of that amount.
Currently, the center is accelerating initiatives like recirculating cooling towers, steam condensate recycling, and full-scale implementation of dew point ventilation. These efforts are expected to bring even greater energy savings, emissions reductions, and cost efficiencies, further solidifying the center’s position in a competitive market.
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