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Successful Problem Solving 6

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Optimization of Scouring prescriptions that we have achieved with our customers

Scouring of the textiles are refined at any dyeing mills in the world. If your company has processing mills in more than one country, you may want to use products with superior performance in other countries...
It is not unusual for the expected performance not to be achieved and processing problems to occur due to differences in processing conditions such as processing machines, chemicals, and water.
Therefore, we will introduce how to deal with the processing problem that occurred when the customer introduced the scouring agent used in other countries and the solution that we found together with the customer.

Long way to come across the solution

STEP 01 Back ground

Expansion of processing in other countries

Our subsidiary PT. INDONESIA NIKKA CHEMICALS (hereinafter INKALI) has received a request from Indonesian dyeing mills that have parent companies in other countries to procure scouring agents on-site in Indonesia. At the beginning, the customer imported the scouring agent used by the parent company. However, since the imported product is expensive, we received a request from the customer to process it with a scouring agent available in Indonesia that can maintain the same processing stability and processing quality as the parent company.
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 Improving production efficiency: Improving work efficiency by responding to automatic dosing machines, Reducing cost.
② Stabilization of  chemical quality: Elimination of mold generation in stock tanks, Without processing troubles, Realization of processing quality equivalent to global (parent company)
③ Reduction of risk associated with chemical delivery: Shortening of lead time

We succeeded this time as our customers and NICCA jointly created the optimum scouring recipe including Scouring agent, Chelating agent and Stabilizing agent. In the future, we will continue to propose solutions to optimize the entire process as well as the development of chemicals.

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.

PT.INDONESIA
NIKKA CHEMICALS
Development and Technology Section

MONICA PUTRI

PT.INDONESIA 
NIKKA CHEMICALS
Development and Technology Section

IKE OKTAMA KRISTY

 

 

PT.INDONESIA 
NIKKA CHEMICALS
Development and Technology Section

NURUL NANING SD

 

 

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