Green and Sustainable Development: Dazheng Special Fiber in Action

1、 Developing Green Sea Components
The main product of Linyi Dazheng Special Fiber New Materials Co., Ltd. is sea island composite short fibers, which are produced using two types of raw materials. The components that are processed during subsequent processing are called "sea components", and the components retained in the final product are called "island components". This kind of product was invented in Japan, and later produced in South Korea and Taiwan, China, China. In the last decade, there have been factories in Chinese Mainland. At present, Dazheng Teflon is a large island composite staple fiber factory in Chinese Mainland.
As of now, the sea components used by island composite short fiber factories in various countries and regions are mainly alkali soluble polyester chips and low-density polyethylene chips. Both materials, as marine components, not only have certain defects and limitations in product quality, but also have varying degrees of damage to the environment.
The disadvantage of using alkali soluble polyester chips as sea components is that sodium hydroxide needs to be used to remove the alkali soluble polyester components from the fibers in the future, which is a chemical reaction. Both alkali soluble polyester and sodium hydroxide are decomposed and cannot be recycled, resulting in resource waste and environmental damage.
The disadvantage of using low-density polyethylene as a sea component is that toluene needs to be used as a solvent to remove polyethylene from fibers in the future. As a highly volatile and toxic organic product, toluene not only damages the health of employees during the production process but also remains in the finished product, which has a certain impact on the health of end consumers.
Considering that both commonly used raw materials as sea components have varying degrees of defects, we have developed a raw material with the following characteristics as a sea component in collaboration with Shanghai Synthetic Fiber Research Institute, with the goal of protecting the environment (denoted by code A for confidentiality). (1) A raw material can be composite spun with various island components such as conventional polyester, various modified polyester, corn fiber, etc., fully utilizing the advantages of various modified polyesters. (2) The reduction process is a physical reaction that does not require high temperature and pressure conditions, and does not produce toxic or harmful substances. (3) Both sea components and solvents used for reduction can be recycled and reused. (4) The economy is good, and the total cost is not higher than the comprehensive cost of existing sea components. At present, sea island short fibers produced using raw material A and conventional polyester have produced final products with various physical properties that meet market requirements. It is expected to achieve mass production by the end of 2021 and is expected to completely replace existing fiber products using alkali soluble polyester and polyethylene as sea components by 2025.
  2、 Produce colored fibers according to customer requirements
In order to pursue visual effects, downstream customers need colored fibers. There are two ways to obtain colored fibers: one is to purchase white fibers through dyeing, and the other is to add corresponding colored masterbatch during fiber production. Dyeing generates a large amount of wastewater, which on one hand leads to the waste of water resources, and on the other hand requires a significant investment in wastewater treatment. Directly discharging wastewater that does not meet the standards will also damage the environment.
We provide customers with the colored fibers they need directly by adding masterbatch of the corresponding color during the fiber production process. This not only protects the environment but also helps improve the color fastness and dry/wet wiping properties of the colored fibers, thereby enhancing product quality.
  3、 Using recycled raw materials
To fulfill more social responsibilities and protect the environment. We use recycled nylon slices and recycled polyester slices to replace native nylon slices and native polyester slices. We have reduced oil consumption, minimized waste, and protected the environment by using recycled raw materials.
The recycled nylon slices we purchase are produced through the following processes: 1. Recycling the blocks, waste fibers, and non-conforming products generated during the production of nylon long and short fibers. 2. Select and clean the impurities in this part of the product to ensure that the impurity content meets the processing requirements. 3. Crush clean waste materials, melt them at high temperatures, wire them, cut them, dry them, and package them for sale. The production process of recycled polyester chips is basically the same.
  4、 Developing polyester cotton separation technology to open up the channel for textile recycling
To achieve the functions of warmth, stiffness, moisture absorption, and sweat wicking in textiles, most textiles are blended with polyester and cotton. This blending method increases the difficulty of recycling, making it difficult for many textiles to be recycled after being discarded, resulting in resource waste and environmental damage. If this technology can be successfully developed, a large number of polyester cotton blended products can be decomposed into cotton and polyester, and processed back to their original state, making our society more beautiful. We have commissioned the Shanghai Synthetic Fiber Research Institute to develop polyester cotton separation technology and have achieved preliminary results. It is expected to achieve mass production by the end of 2022.