The processes of cotton knitting fabric(scouring, bleaching , dyeing and etc.) is generally carried out in the overflow machine. During the entire processing, the fabric remains in a rope-like state. The fibers constantly bend and deform in the dyeing machine, the original hydrogen bonds are constantly broken while new hydrogen bonds are constantly formed. Sometimes the newly formed hydrogen bonds cannot be fully restored, thus forming chicken claw marks and dead creases on the fabric surface.

In the single-sided fabric structure, tension of the two sides of yarn is asymmetric. After fabric is folded in one direction for a long time, it is difficult to recover. Therefore, among various structures,  especially on fabrics with less or larger weight (eg. plain weave and sweatshirt fabrics) are more prone to crease problems. The generation of creases is also closely related to yarn count and twist. The finer the yarn count and the higher the twist, the greater the possible reversal and untying of the yarn, and the more likely it is to cause crease problems.

 

 

The main process steps leading to creases: scouring and bleaching

1. The general dyeing and finishing process typically involves: fabric preparation → seam sealing → boiling and bleaching in the fabric dyeing machine → dyeing → soaping → color fixing → softening → fabric out from dyeing machine → dehydration → drying. It is commonly believed that creases mainly form in the dyeing machine. However, after rigorous experimental verification by our engineers, it has been found that most cotton knits actually develop creases during the boiling and bleaching stage, which are just not easily observable before dyeing.

 

2. Based on the years of experience of our engineers, the following types of fabric and equipments are prone to developing creases during the boiling and bleaching stage:

Fabric factors: Single-sided cotton fabrics with lighter or heavier weights (e.g., weights <150g or >300g), especially cotton spandex (with elastane) fabrics.

 

Machine factors: Compared to L-shaped overflow fabric dyeing machine, J-shaped overflow fabric dyeing machine are more prone to creating creases due to their stronger stretching force. Air-jet fabric dyeing machine, on the other hand, are less likely to cause creases because the fabric is fully blown open by high-pressure air at the nozzles, allowing the fibers to "rest" from tension, which aids in eliminating internal stress and reducing creasing issues.

 

Process factors: Fabrics that have not undergone prestretching are more prone to creasing. Fixing the fabric under high temperatures can improve fiber proximity and orientation, stabilize fiber morphology and reduce likelihood of changes occurring in dyeing machine, which is beneficial for reducing creases.

350g pure cotton knitted fabric (no creases after dyeing)

 

140g pure cotton knitted jersey (no creases after dyeing)

 

Solutions of scouring and belaching creases 

1. General Method: During boiling and bleaching, as well as dyeing, polyacrylamide-based lubricants are added. The primary role of this type of lubricating agent is to "reduce friction between fabrics and between fabrics and machinery," but it is difficult to resolve creases formed during boiling and bleaching.

 

2. Solution Proposed in This Article: To improve creases during boiling and bleaching, the following auxiliaries, processes, and operations are employed. Satisfactory results have been confirmed through applications by multiple clients.

 

Auxiliaries:

A. Preferentially select a high-concentration and highly soluble polyacrylamide-based anti-crease agent JET (non-ionic) for use in the bath. Its role is to reduce friction between fabrics and between fabrics and machinery.

B. Select new type of anti-crease softener RCE (non-ionic). Its role is to impart good softness and smoothness to the fabric itself, as well as to provide level dyeing properties. 

The combined use of these two auxiliaries is the core of this method.

 

Process:

Reduce the heating rate; the focus is on reducing the cooling rate, with an optimal range of 1.0 to 1.5°C/min.

 

Operations:

Before entering the dyeing machine, the gray fabric should be placed in an area with high humidity in workshop to allow for sufficient moisture regain. During moisture regain, the fibers undergo some swelling, and internal stresses are partially eliminated, which is conducive to reducing creases. After the gray fabric is loosened, it should be allowed to freely pass through a J-shaped trough, while simultaneously being pressed by a press roll or stretched by rollers, which is conducive to eliminating internal stresses and reducing creases.

 

3.Process example

Before boiling and bleaching, add refining permeant, etc., anti-wrinkle agent JET and anti-wrinkle softening agent RCE in the bath, do not heating firstly, cycle for 20 minutes after entering the cloth, so that the grey cloth is fully moistened and the auxiliary agent fully reacts with the fabric fiber. If bleaching is required, caustic soda and hydrogen peroxide can be added before heating. Reduce the rate of heating; Especially to reduce the cooling rate, generally 1.0 ~ 1.5℃/min is better; And it must be completely cooled to 50 ° C to discharge the liquid for dyeing.

 

Other items to prevent creases

1. In order to prevent the generation of creases, it is recommended to add polyacrylamide type lubricant - JET in the bath during dyeing, and reduce the cooling rate.

2. When dehydrating and dry cloth, open width rolling water dry cloth can be used, which not only improves the efficiency of dry cloth, but also helps to solve the problem of creasing. 

3. When stacking cloth, it is recommended that the weight should not be too large and the time should not be too long, especially when the wet cloth is stored.

4. If it is cotton rack (with spandex) fabric using this solution can not completely solve the crease problem, you can consider the presetting process. 

 

5. Generally, the slight crease can be solved by the setting machine, and the stubborn can be returned to the cylinder washing water, gradually heating up to 85 ° C, gradually cooling down to 50 ° C process test repair, or can be re-shaped by steam in the industrial drying machine, which can be repaired according to their respective equipment and crease conditions.

Textile dyeing machines are industrial equipment designed for the dyeing or coloring process of textiles. Dyeing is a critical step in the textile manufacturing industry, where dyes are applied to fabrics, yarns, or fibers to achieve the desired color or pattern.

 

I. Market Research

1. Market Size and Growth Trends

According to the latest report by QYResearch, “Global Textile Dyeing Machine Market Report 2023-2029,” it is expected that the global textile dyeing machine market will reach $1.37 billion by 2029, with a compound annual growth rate (CAGR) of 4.2% in the coming years. This indicates that the textile dyeing machine market will experience steady growth over the next few years.

 

2. Development Trends

Digitalization and Automation: With the continuous development of artificial intelligence, big data and other technologies, the textile dyeing machine industry is gradually moving towards digitalization and automation. The application of intelligent equipment not only improves production efficiency but also reduces production costs and enhances product quality.

 

Environmental Sustainability: With the increasing global awareness of environmental protection, eco-friendly solutions have become a mainstream trend in the textile dyeing machine industry. Major companies are adopting environmentally friendly production technologies and materials to achieve sustainable development.

 

Customization and Personalization: As consumer demand becomes more diverse, personalized and customized textile products are increasingly favored. Textile dyeing machine companies need to offer a variety of products and services to meet consumers' individual needs.

*knitted fabric dyeing machine

 

3.Potential Growth Drivers

Sustained Market Demand: With the global economic recovery and the improvement in consumer purchasing power, the demand for textiles continues to rise, providing significant growth opportunities for the textile dyeing machine market.

 

Emerging Markets: Emerging markets in Southeast Asia, Africa, and other regions offer vast growth potential for the textile dyeing machine industry.

 

Technological Innovations: New dyeing technologies such as digital dyeing and smart dyeing are constantly emerging, bringing new development opportunities to the textile dyeing machine market.

 

4. Potential Challenges

Environmental Pressure: With the tightening of environmental regulations, textile dyeing machine companies need to increase investments in environmental protection and improve the eco-friendliness of their products.

 

International Trade Barriers: Green trade barriers are becoming a significant factor limiting textile exports, requiring the textile dyeing machine industry to focus on green production.

 

Intense Market Competition: The domestic and international markets are highly competitive, requiring textile dyeing machine companies to continuously improve product quality and technological capabilities to stay ahead of the competition.

 

II. Industry Competitor Analysis

1. Major Manufacturers

Globally, leading manufacturers of textile dyeing machines include COSMOTEX, Gargo Corporation, Sclavos, Texfab, Thies, Chemtax, M/s Exolloys Engineering, Capto, and Loris Bellini. The top three companies account for approximately 54.9% of the market share.

 

2. Strategic Positioning and Competitive Advantages

Large Multinational Companies: These companies typically possess strong R&D capabilities and advanced technological expertise, allowing them to produce high-end, intelligent dyeing machines. They enjoy significant global market share and brand recognition. These companies focus on technological innovation and product quality, continuously introducing advanced dyeing machine models that meet market demands.

 

Small and Medium-Sized Local Enterprises: Compared to large multinational companies, small and medium-sized local enterprises also occupy a certain share of the textile dyeing machine market. They typically serve local markets by offering flexible production methods and personalized services.

 

3. Competitive Disadvantages

Some small and medium-sized enterprises lack sufficient investment in R&D and product innovation, resulting in weaker product competitiveness.

Some companies lack an international perspective and brand influence, making it difficult to secure a dominant position in the global market.

*small capacity fabric dyeing machine

 

III. Supply Chain Structure Analysis

1. Supply Chain Efficiency

The textile dyeing machine industry’s supply chain includes raw material suppliers, component manufacturers, machine manufacturers, distributors, and end users. Currently, there is a high degree of collaboration and coordination between different supply chain stages, leading to overall high efficiency.

 

2. Potential Bottlenecks

Raw Material Supply: The supply of some critical raw materials may be affected by market fluctuations, trade policies, and other factors, potentially leading to bottlenecks in the supply chain.

 

Technological Innovation: Technological innovation is a key driver of industry development, but some enterprises' insufficient investment in R&D may slow the overall improvement of supply chain technology.

 

IV. R&D Progress and Technological Innovation

1. New Dyeing Technologies

Emerging technologies such as digital dyeing and smart dyeing are creating new opportunities for the textile dyeing machine industry. These technologies not only improve dyeing efficiency and product quality but also reduce energy consumption and pollutant emissions.

 

2. Intelligent Production Lines

Intelligent production lines are an important development direction for the textile dyeing machine industry. By integrating smart equipment, companies can automate and optimize the production process, leveraging big data and cloud computing technologies to enable real-time analysis and processing of production data, thus improving production efficiency and product quality.

 

3. Application of New Materials

The development and application of new materials, such as functional fibers, smart fibers, and eco-friendly fibers, provide more possibilities for the textile dyeing machine industry, driving innovation and development.

*hank yarn spray dyeing machine

 

V. Regulatory and Policy Environment Analysis

1. Environmental Regulations

With increasing global environmental awareness, governments worldwide are strengthening the formulation and enforcement of environmental regulations. Textile dyeing machine companies must comply with these regulations, increasing their environmental investments and improving the eco-friendliness of their products.

 

2. Industrial Policies

During the “14th Five-Year Plan” period, national policies are placing higher demands on ecological civilization construction. The "3060" carbon neutrality goal will push the printing and dyeing industry to adopt more proactive and practical measures, such as technological innovation and pollutant control, to improve energy and resource efficiency, reduce pollutants, and achieve a balance between economic, ecological, and social benefits.

 

3. International Trade Policies

The rise of international trade protectionism and green trade barriers has impacted the export of textile dyeing machines. Companies need to closely monitor changes in international trade policies, strengthen international trade cooperation, and improve their products' international competitiveness.

The textile dyeing machine industry is expected to maintain steady growth in the coming years. However, it also faces many challenges. Companies need to continually enhance their technological innovation capabilities and product quality, adapt to changes in market demand, expand their market share and achieve sustainable development.

 

FLANNEL

Material:Originally made of wool, now also available in polyester and other synthetic fibers as imitation flannel.

Appearance & Feel: Short and dense fine hairs, tightly structured, resistant to deformation, good gloss, and soft to the touch.

Properties: Excellent moisture absorption and breathability, strong insulation, and minimal shedding.

 

Applications: Commonly used in suits, trousers, bedding, etc.

 

CORAL FLEECE

Material: Made of polyester fibers.

Appearance & Feel: Long and dense hairs resembling the soft body of live coral, colorful, and soft to the touch.

Properties: Good insulation, but the longer the hairs, the poorer the moisture wicking ability; not prone to pilling but prone to shedding.

Applications: Often used in making robes, pajamas, baby products, children's clothing, footwear, hats, toys, etc.

 

POLAR FLEECE

Material: Generally made of polyester fabric, with the option to add a certain percentage of spandex (which can be difficult to control in quality).

Appearance & Feel: The front side has fluffy and dense loops, while the back side has sparse and uniform loops with short hairs, feeling soft to the touch.

Properties: Elastic, insulating, wear-resistant, non-shedding, mold-resistant, moth-proof, good elasticity, and resistant to wrinkles and deformation.

Applications: Commonly used in outerwear, children's clothing, hoodies, cold-weather outerwear, loungewear, etc.

 

POLYESTER SHERPA

Material: Synthetic fabric made of pure polyester or blend of polyester and acrylic fiber.

Appearance & Feel: Relatively long and fluffy hairs resembling lamb's wool, feeling soft to the touch.

Properties: Wear-resistant, mold-resistant, moth-proof, good elasticity, and resistant to wrinkles and deformation.

Applications: Often used in making outerwear, loungewear, hats, toys, etc.

 

MILK FLEECE

Material: A new type of animal protein fiber made from milk as the basic raw material, after dehydration, degreasing, purification, and blending, crosslinking, and grafting with polyacrylonitrile.

Appearance & Feel: Short and dense hairs, treated for softness, silky smooth like milk, good gloss, and soft to the touch.

Properties: Excellent moisture absorption and breathability, strong insulation.

Applications: Commonly used in bedding, high-end underwear, etc.

 

VELVET

Material: Silk fabric woven with silk or artificial silk loops and cotton yarn as the weft.

Appearance & Feel: Luxurious and elegant appearance, dense pile hairs, long and slightly inclined, silky smooth to the touch.

Properties: Good insulation, bright gloss.

Applications: Can be used to make autumn and winter clothing, hats, silk velvet blankets, and decorations, as well as high-end sofa covers, curtains, etc.

 

These fabric can be dyed by TY-JL636 series high temperature high pressure low tension fabric dyeing machine, according the width and GSM fabric can be adjusted the nozzle size. 

Fibre soft and slender substance with length to diameter ratio at least 10:1,  the cross-sectional area less than 0.05mm2. For textile fibers, the ratio of length to diameter is generally greater than 1000:1. 

About textile fibers: Natural fiber, such as cotton, hemp, wool, silk and so on; Chemical fiber refers to natural or synthetic polymers as raw materials, through chemical methods and mechanical processing made as fiber.

 

1) According to the source of raw material: Regenerated fibre and Synthetic fibres

• Regenerated fibre also be called as synthetic fiber, using natural polymers or lost textile processing value of fiber raw materials through a series of chemical treatment and mechanical processing be fiber again, the chemical composition of the fiber and original polymer is alomost same. Including Regenerated cellulose fibre (such as viscose fiber, copper ammonia fiber), Regenerated protein fiber  (such as soy protein fiber, peanut protein fiber), regenerated inorganic fiber (such as glass fiber, metal fiber)  and regenerated organic fiber (such as chitin fiber, seaweed gum fiber).
• Synthetic fiber is made of natural low molecular compounds such as petroleum, coal, limestone, natural gas, salt, air, water and some agricultural and sideline products as raw materials, through chemical synthesis and processing be fibers. There are seven common types of synthetic fibers: polyester fiber (polyester), polyamide fiber (nylon), polyacrylonitrile fiber (acrylic fiber), polyvinyl formaldehyde fiber (vinylon), polypropylene fiber (polypropylene), polyvinyl chloride fiber (chlorinated fiber) and polyurethane elastic fiber (spandex), etc. 

   

   

  2) Classification by morphological structure: Continuous filament and Staple fibre

  • Continuous filament 

    During chemical fiber manufacturing process, spinning fluid (fusant or melt) after spinning forming and post-processing, the length of fiber is caiculated in kilometers is called chemical fiber filament. Chemical fiber filaments can be divided into monofil, multifilaments, twisted fibers, double twisted fibers, cord fibers and Textured filament.

    Monofilament: A single continuous fiber of very long length.

    Multifilaments: A filament composed of two or more single filaments joined together. Complex filaments of chemical fibers are generally composed of 8 to 100 single fibers.

    Twist yarn: twist Multifilaments  becomes twist yarn.

    Double twist yarn: Two or more strands of twist yarn are combined to be double twist yarn.

    Cord wire: composed of more than one hundred to several hundred single fibers, used to make tire cord fabric.

    Textured filament yarn: The chemical fiber filament is deformed and processed so that it has the appearance characteristics of curling, spiral, ring and so on, showing fluffy and flexible filament.

    • Staple fibre

      The product of the chemical fiber is cut into few centimeters to dozen centimeters in length, it is called staple fiber. According to the different cut length, staple fibers can be divided into cotton type, wool type and medium long staple fibers.

      The length of Cotton type fibre is 30 ~ 40mm, the linear density is about 1.67dtex, the fiber is fine, similar to cotton. The length of Wool type fibre is 70 ~ 150mm, the linear density is 3.3 ~ 7.7dtex, the fiber is thicker, similar to wool; Mid fibre has a length of 51 ~ 65mm and a linear density of 2.2 ~ 3.3dtex, between cotton type and wool type.

       

      3)  Classification by fiber manufacturing method

      Chemical fibers can be divided into two categories according to the basic manufacturing methods,  melt spinning fibers and solution spinning fibers (i.e. dry spinning fibers and wet spinning fibers).

      • Melt spinning is polymer melt is pressed out of the spinneret hole, melt is solidified into silk in the surrounding air (or water).
      • Dry-spinning is polymer concentrated solution is pressed out from the spinneret hole form as trickle, solvent evaporates rapidly in hot medium and solidifies into silk. 
      • Wet spinning is polymer concentrated solution is pressed out of the spinneret hole and solidified into silk in a coagulation bath.

         

        4) Classification by composition within a single fiber

        • Single-component fibers: Fibers composed of the same polymer are called single-component fibers, and most conventional fibers are single-component fibers, such as polyester.
        • Multicomponent fibers:Fibers composed of two or more polymers are called multicomponent fibers, such as acrylic fibers. 
        • Composite fiber:the components are arranged regularly along the fiber axis and form a continuous interface fiber.
        • Blended fiber: components are randomly dispersed or more evenly mixed fiber

           

          5) Classification by fiber difference

          • Differential fibre: chemical fiber that has undergone chemical or physical changes to differentiate it from conventional fibers. Such as profiled fiber, composite fiber, microfiber, easily dyed fiber, flame retardant fiber, hydrophilic synthetic fiber, colored fiber and anti-pilling fiber.
          • Functional fibre: except existing properties of the fiber, attach some special functions. Such as conductive fiber, optical fiber, ion exchange fiber, ceramic particle fiber, temperature control fiber, radiation fiber, bioactive fiber, biodegradable fiber, can produce negative ion fiber, antibacterial and deodorizing fiber.
          • High-performance fibre: special fibers with a strength of 17.7cNhttps://www.yarnfabricdyemachine.comdtex and a modulus of 441.5cNhttps://www.yarnfabricdyemachine.comdtex. Such as carbon fiber, aromatic polyamide fiber, polybenzimidazole fiber, polyphenylene sulfide fiber and ultra-high molecular weight polyethylene fiber.

             

            Whether it is natural fiber or chemical fiber products: Hank yarn, package yarn, fabric, top, loose fiber etc., Wuxi Shin Tong Yunn Machinery can provide  corresponding dyeing equipment(hank yarn dyeing machine, cone yarn dyeing machine, fabric dyeing machine, garment dyeing machine etc.) and finishing equipment(yarn extractorhttps://www.yarnfabricdyemachine.comfabric dehydrator, yarn dryeing machine, fabric drying machine etc.), welcome to visit our factory and website.