Problem Solving 6 | NICCA Textile Chemicals

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Optimization of Scouring prescriptions that we have achieved with our Indonesian customers

NICCA Group develops textile processing agents and proposes optimal processing recipes to contribute to improving productivity and stabilizing processing quality at dyeing mills. This time, we would like to introduce the success story of scouring method established by our group company PT. INDONESIA NIKKA CHEMICALS (hereinafter INKALI) together with our customers. This is a content that can be used not only in Indonesia but in any country, so please check it.

Global dyeing companies in multiple countries aim to achieve the same processing quality in all factories. When the conventional processing is transferred to another country or the same processing is performed in multiple countries such as new factories and line expansion, the quality and physical properties of the processed products often differ. These are problems that occur due to differences in processing conditions such as the processing machines used by the dyeing mill, the chemicals used in combination, and the water used. For these problems that dyeing mills have, it is necessary to actually go to the site, identify the factors and the issues, develop processing agents that match each processing condition, and find processing method.

Long way to come across the solution

STEP 01 Back ground

Establishment of continuous bleaching method for Cotton and T/C fabrics

INKALI received a request from a global company that owns dyeing mills in multiple countries to provide locally procurable scouring agents. Initially, customers imported the scouring agents used in dyeing mills in other countries into Indonesia. However, since imported products are expensive, we received a request to process them with a scouring agent that can be procured locally in Indonesia, which can maintain the same processing stability and processing quality as conventional products. In this way, INKALI and its customers began examining alternatives to scouring agents, and as they proceeded with their studies, various problems became more apparent.

STEP 02 Discovery of the factors

Productivity and Quality

When we began examining scouring agents, we found various problems in the on-site scouring processing.
First of all, since the scouring agent used by the parent company is a highly concentrated product, dilution preparation was required in the stock tank. We found that there were problems with productivity and quality, such as laborious efforts for dilution work by workers and mold generation in stock tanks.
Therefore, while confirming the processing conditions and formulations of our customers, we undertook in-house production from raw materials in Indonesia, and began efforts to develop a scouring agent that does not require dilution and processing prescription that has the same performance as conventional products.

STEP 03 Product Development

Towards the realization of optimal scouring processing

There were a number of barriers to developing scouring agents and processing. In spite of the acceptance level of the performance evaluation in INKALI Laboratory, it failed in the evaluation by the customer. When the cause was confirmed, it was found that the evaluation method differed between NICCA and the customer. Therefore, we repeatedly evaluated the customer's evaluation method until the same performance was obtained. In addition, in the performance evaluation of the scouring agent on the actual machine, we made improvements until a product and a processing recipe were obtained that were balanced in every performance such as scouring, foamability and viscosity that can be supported by an automatic dosing machine.
Consequently, we developed "SUNMORL UM-209", a scouring agent for Cotton and Polyester/Cotton that clears scouring, foaming, and viscosity issues. In addition, by selecting not only Scouring agents but also Chelating and Stabilizing agents, a series of processing agents necessary for scouring and bleaching cotton, we have reached the establishment of a scouring recipe for continuous processing with excellent alkali resistance and penetration.

STEP 04 Reaching to the Solution

Significantly contribute to Improving Production Efficiency and Processing Quality!

The present proposal for scouring process has provided a variety of benefits to our customers.
(1) Stabilization of processing quality: Achieves processing of equivalent quality globally, No processing trouble
(2) Improvement of production efficiency: Improvement of work efficiency by supporting automatic loading machine, Elimination of mold problem in stock tank
(3) Local procurement of chemicals: Shortening lead time, Reducing costs

We succeeded this time as our customers and NICCA jointly created the optimum scouring recipe including Scouring agent, Chelating agent and Stabilizing agent. As a solution provider, we will continue to contribute to the provision of high-quality textile products while optimizing the entire processing process.

Comments from the customer

"SUNMORL UM-209" is a 4 in 1 pre-treatment product. It has a good pre-treatment wetting agent with strong emulsifier effect plus low foaming property and also can withstand high concentration until 10-12 Baume NaOH. Am happy and big thanks for INKALI R&D team developed this special product and finally it replaced the imported item with similar performance.

R&D Person in Charge

We would like to contribute to improving the work environment and convenience of our customers!
Based on this philosophy, we challenged the development of a new refining agent that can also contribute to improving the cost performance of our customers, and created "SUNMORL UM-209".
We will continue to research the optimal processing method that will please our customers.