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updated on March 18, 2019

Realization of a splitting/dyeing process for microfibers which will reduce the burden on the environment

Tsuyakin Kagakuseni Co., Ltd.

Project name Development of a technology of integral splitting/ dyeing processing that realizes high-function and high-sensitivity microfiber products while saving energy
Target downstream fields Clothes / fiber
Response to the needs of downstream companies High function (improved precision / performance)
Optimization (improved productivity / work efficiency)
Environmental considerations (removal and detoxification of impurities / waste reduction / CO2 reduction)
Reliability / safety (realization of highly reliable inspection technologies etc.)
Cost reduction (running cost reduction / loss elimination / labor saving)
Specific numerical values relating to the above needs Splitting/dyeing processing of fibers with a single-fiber diameter of 700 nm
Project implementation period 2012~2013
Commercialization status Commercialization completed (Already has sales results)
Target materials Knit fiber

Project details

Project background
Users of microfiber fabrics were calling for a splitting/dyeing processing technology for knit structures consisting of nano-order fibers. However, such technology was impossible with existing equipment. We therefore aimed, by making nano fiber splitting processing technology more advanced, to establish knit structure processing technology that could utilize nano fibers' high-function properties (arising from the effects of their having a large surface area) and high-sensitivity properties (arising from their unique texture), and also to develop technology that could satisfy users' requirements for high-function, high-sensitivity products.
Points of R&D
With conventional splitting technology, there was an issue of unstable traveling of knit fabrics due to a large decrease in the material's weight after splitting. This weight decrease also caused also caused many problems in the dyeing process in connection with the handleablity of the fabric. To address these issues, we developed an energy-saving processing machine that could integrate splitting and dyeing processing, and a high-efficiency splitting/dyeing processing program . Using the technology we had developed, we conducted trial processing of knit fabrics using nano split fibers.
Specific R&D results
A processing machine that can integrate splitting and dyeing processes was developed in order to achieve processing of knit fabrics made of split fibers with post-splitting single-fiber diameters on the nano order. Through the development of a variety of systems, a fully automatic, energy-saving splitting/dyeing processing machine was developed which had environmental burden reduction systems that could reduce the amount of processing fluids/agents, the amount of energy used and more. The minimum conditions for the splitting process using the processing machine we had developed were examined and determined, and various control programs were established in response. A mass production processing machine was developed to make it possible to carry out mass production applying the developed technologies.
Anticipated fields / products etc. to which this technology may be applied in the future
The splitting/dyeing processing technology we developed enabled us to improve hygroscopicity, thanks to an increased surface area compared with fibers already on the market which resulted from the use of ultrafine fibers. It also enabled us to achieve a high drape performance like silk and substantially suppress friction coefficients. In addition, it provided special properties such as a substantially improved wiping performance due to a smaller fiber diameter than those of oil film or fine dust. Applications in various fields and for various purposes, such as clothes which are outstandingly comfortable to wear, highly functional sportswear, filters, materials for clothes for care work and high-performance wipers can be expected to result from utilizing these properties.

Work toward commercialization

Commercialization status and scale Starting this fiscal year, we have received requests for mass production testing of splitting/dyeing processing from a downstream company, for fabrics mainly used to make spectacles cloths etc., the yarns for which are comparatively thick for a microfiber. Although establishing responses to some new issues which did not come to light during the Supporting Industry Program took some time, we were able to obtain a certain level of results.
Effects of commercialization We have been working only on dyeing and finishing of fabrics for clothes since our company was founded, and that has not changed. Microfibers, on the other hand, are not used for clothes, but for spectacles cloths and other industrial purposes. As a company, we have won ourselves some business in a new field, and we can expect the scope of our business to expand from here on. We were also recognized as a development partner by an adviser during the implementation of the Supporting Industry Program, and there is a possibility that we will participate in discussions related to commercialization of nano fiberglass.
Activities related to intellectual property and publicity N/A
Future outlook Currently, the scale of the microfiber business is smaller than that of the clothes fiber business, but it has the potential to grow into a larger market. In addition, it is said that Japanese companies' accumulation of technology in this field is one step ahead, and we will continue to work actively to expand our business.
Level of achievement based on the original goal, and new challenges We have learned that for splitting/dyeing processing of microfibers, besides the processing machine that was the central subject of the Supporting Industry Program, management methods different from that of fabrics for clothes are required in all the processes, including drying and inspection. In order to establish these methods, we must continue our development work and capital investment.
Inquiries from downstream industries 1 inquiry about microfiber splitting/dyeing processing

System of R&D

Organization managing the project Public Interest Incorporated Foundation Gifu Economic and Industrial Promotion Center
Certified business operators Tsuyakin Kagakuseni Co., Ltd.
Institutions conducting the research Tsuyakin Kagakuseni, Co., Ltd., Industrial Technology Center, Gifu Prefectural Government
Advisers Toray Industries, Inc., Amano Co., Ltd., Marugen Co., Ltd.

Promotion comments

Processing technology for split fiber yarns is virtually monopolized by major synthetic polymer fiber manufacturers and the details of their technologies are closed in black boxes. The technology we developed in this project will lead to an expansion of technological capabilities in the dyeing and finishing industry (which has many small‐ and medium-sized enterprises), and will make it possible to upgrade our technological capabilities and distinguish them from those of Chinese companies. Although the microfiber market is still developing, it is predicted to expand in the future, and business expansion can be expected based on the environmentally-friendly microfiber processing technology we have developed. We believe that the technology we have developed can be extended to processing technologies that will contribute to the creation of fashions that will make it possible to provide design concepts and functions based on new sensibilities. Against a background of a harsh environment both inside and outside, we will be able to develop ourselves into an autonomous small- and medium-sized company with a high level of corporate power.

Corporate information

Company name Tsuyakin Kagakuseni Co., Ltd.
(Corporate Number:9200001020340)
Address 1050 Takahata, Juroku-cho, Ogaki-shi, Gifu-ken, JAPAN
Phone number +81-584-92-1821
Number of employees 118(male  78,female  40)
Capital 90 million yen
Business category Textile industry
Business content Development of a technology of integral splitting/ dyeing processing that realizes high-function and high-sensitivity microfiber products while saving energy
URL http://www.tsuyakin.co.jp/
Production facilities owned and specifications 32 high pressure dying machines, 30 normal pressure dying machines, 1 biomass boiler
Production base area Domestic location:1050 Takahata, Juroku-cho, Ogaki-shi, Gifu-ken
Overseas production response Not available
Main clients The Japan Wool Textile Co., Ltd., Toray Industries, Inc., Kurabo Industries, Inc., Kuraray Trading Co.,Ltd.
Department handling inquiries for this project
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