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One-step method: Sirk reverses traditional spinning process
In late 2011, the "One-step Different Shrinkage Mixed Fiber Industrialization Complete Technology and Application Project" was awarded the first prize for Science and Technology Progress by the China Textile Industry Federation. This groundbreaking technology marked a significant leap in the field of chemical fiber production worldwide, ushering in a new era of spinning innovation. The project’s main entity, Xuzhou Silke Fiber Technology Co., Ltd., quickly gained recognition within the industry due to its pioneering efforts.
Established in 2003, Jiangsu Serge Group was among the first high-tech enterprises to respond to the Jiangsu Provincial Party Committee and Government's initiative to transfer industries to Northern Jiangsu. After nearly a decade of growth, the group now consists of nine companies, including its parent company, Jiangsu Serge Group Co., Ltd., as well as subsidiaries like Xuzhou Sergey Fiber Technology Co., Ltd. and Xuzhou Rongshengda Fiber Products Technology Co., Ltd. With an annual production capacity of 56,000 tons of different shrinkage composite yarn and 140 million meters of various textile and apparel fabrics, the group has become a major player in the industry.
At the heart of this success is Sun Derong, Chairman of Xuzhou Silke Fiber Technology Co., Ltd., who emphasizes that innovation is the key to sustained market leadership. His philosophy has driven the company from its early days into a path of independent research and development, challenging traditional methods. The conventional two-step spinning process—where POY and FDY are spun separately and then combined—has long been plagued by issues such as poor quality stability and limited variety. These limitations made it unsuitable for advanced spinning applications.
To address these challenges, Sun Derong led the development of a one-step spinning technology. At the time, this approach was virtually unexplored in China, with few global precedents. Despite the lack of existing models, the team persisted, forming a collaboration with leading experts and institutions, including the Chinese Academy of Engineering’s Academician Jiang Shicheng, Donghua University, and the China Textile Science Research Institute. They successfully developed and industrialized a one-step 24-head spinning process, becoming the first in the world to achieve this feat.
The benefits of the one-step method are clear. Compared to the traditional two-step process, it reduces land use by 46% and plant area by 57%. Energy consumption per ton of product drops by 41%, and material usage decreases by 15 kg per ton. As a result, the cost per ton of product is reduced by over 1,000 yuan. Additionally, the process has overcome critical technical barriers, such as precise control of tension between POY and FDY, and high-speed network compounding. This allows for the production of a wide range of high-value-added fibers, including PET, heterogeneous, fine-denier, and ultra-fine denier composite yarns.
Sun Derong also credits the company’s commitment to science and technology for its success. The group has invested heavily in R&D, spending a total of 67.65 million yuan between 2008 and 2012. They have established multiple research centers and innovation platforms, including the only enterprise academician workstation in the textile industry and several provincial engineering technology research centers. Their collaboration with Zhongli Machinery further exemplifies their forward-thinking approach. Although the initial equipment was met with skepticism, the resulting success not only validated their vision but also helped Zhongli gain widespread recognition in the market.
Beyond technological advancement, the company focuses on differentiation to stay ahead. For example, they developed a unique color silk fabric that won the “Best Technology Innovation Award†at the 2012 Chinese spring and summer popular fabric competition. Their shading cloth, which uses structural changes in fibers instead of coatings, offers long-lasting performance and environmental benefits. This innovation has made them a leader in the home textile market.
Looking ahead, Sun Derong remains committed to innovation and differentiation. By continuously developing new products and maintaining a competitive edge, the company ensures it stays one step ahead in the ever-evolving textile industry.