In 2007, Yihua Filament Center faced intense competition from conventional products. With an investment of 180,000 yuan, the center successfully transformed its production line to produce high-value POY fine denier porous filaments, significantly increasing annual gross profit by nearly 2.5 million yuan. This marked a key step in adapting to market challenges, as the center focused on technological upgrades and innovation over the past two years, enhancing device efficiency and product quality while expanding its production capacity.
The domestic filament market has long suffered from overcapacity, with many advanced private enterprises investing after 2004, boasting superior technology, high efficiency, and strong market competitiveness. In contrast, the Filament Center’s final production line was installed before 2001. To bridge this gap, the center launched a comprehensive technical innovation plan, assigning specific departments and personnel to drive technological breakthroughs and develop new products, aiming to improve product value and reduce the competitive gap.
One such initiative involved the FDY52 line, which previously produced only conventional FDY with low added value and high losses. Through extensive market research, the center decided to retrofit this line, enabling it to produce higher-priced, more competitive products. The transformation expanded production capacity and improved market position. Similar innovations were later applied to the FDY53 and FDY54 lines, introducing dual-end spinning technology that allowed for the production of fine denier FDY, boosting profits by around 300 yuan per ton annually. This helped stabilize income during off-seasons and reduced the risk of operational downtime.
Another critical area of innovation was in meeting the strict requirements of high-end customers. A joint venture in Zhejiang, producing premium home textiles for export, demanded high-quality raw materials. Even if cheaper alternatives were available, they were not acceptable. In response, the Filament Center began R&D on FDY55 and FDY56 lines, focusing on improving process control—such as spinning temperature, draw ratio, and spindle positioning—to achieve high and low shrinkage rates. This led to the successful production of a popular felt material, surpassing the quality standards of local private enterprises and securing growing orders.
Quality improvement became another core focus. The center realized that even minor defects could lead to customer complaints. By engaging directly with users, they learned that true quality was reflected in how well the product performed in use. Addressing long-standing issues like black and yellow paste components, the team redesigned the filter structure and modified the distribution board (φ85), reducing the occurrence of such defects from 35-40% to zero. On lines 60 and 61, they extended component connection blocks to meet the quality demands of KDY products. After implementing double-spinning technology for fine denier filaments, the center also refined winding parameters and improved paper tube quality, ultimately eliminating user complaints entirely by the end of 2007.
Energy conservation and emission reduction were also priorities. In 2007 and 2008, the company set energy-saving targets of 3–5% for the Filament Center. To meet these goals, the center formed multiple technical teams to implement new technologies, processes, and materials, significantly improving energy efficiency. In 2007 alone, the comprehensive energy consumption rate dropped by 3.11%, and year-on-year savings reached 6.68%.
A notable achievement was the replacement of chilled water with the power plant’s circulating water system. This required overcoming a technical challenge: connecting the circulating water pipeline to the cooling system without stopping operations. Using a newly developed pressured open hole technique, the team successfully drilled a 500 mm hole into an 1100 mm diameter pipeline, enabling full integration. This allowed the chiller to be shut down during winter, saving nearly 370,000 yuan at a fraction of the cost.
Currently, the center is accelerating projects like recirculating cooling towers, steam condensate recycling, and full-scale implementation of dew point ventilation. These initiatives are expected to deliver even greater energy savings, emissions reductions, and cost efficiencies, marking significant progress in operational performance and sustainability.
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