Last year, Hyosung succeeded in developing the CD PET Continuous Polymerization Process, a feat that nobody could achieve before. The technology was miles ahead of the traditionally used method, and the achievement was the talk of the global textile community. Hyosung’s research team opened a new chapter of history. I met the heroes of this feat at the 2018 IR52 Jang Young-sil Awards Ceremony.
The 2018 IR52 Jang Young-sil Awards (3rd quarter) Ceremony was held on August 28. As one of Korea’s leading industry awards, the Jang Young-sil Award is given to research organizations that develop products and technology competitiveness recognized as the best in Korea. Hyosung received the 32nd week’s IR52 Jang Young-sil award for its development of PRISMA, a “high positive ion dyeing (CD) polyester (PET) fiber” it developed for the first time in the world using a continuous process. The recipients of the award were the individuals who led the development: Team Leader Kim Moo-song of the Hyosung R&DB Labs Polymerization Process Research 1 Team; Assistant Team Leader Oh Seung-taek; and Team Leader Lee Sang-gon of the PET Polymerization Team at Hyosung’s Ulsan plant.
Unlike ordinary PETs, CD PET can produce colorful and clear dye color because it is manufactured using a high-temperature/high- pressure process, and it is very much sought after by customers. The market size is growing by 15-20% every year. In 2016, Hyosung's CD PET sales volume was about to surpass the production capacity. Hyosung was not the only company facing the dilemma of production not keeping up with the demand. To resolve this problem, competitor companies as well as nations jumped into the development of a continuous polymerization process. Hyosung also launched a research project for the development of a CD PET continuous process development. This is when Team Leader Kim Moo-song joined the effort.
“The traditional process was a batch-type process; production proceeded to the next step only after the current process was completed. This characteristic severely limited the production capacity and increased the production time and costs. Quality deviations were also a serious problem. To address these issues, our researchers focused all their efforts on developing technologies that would enable a process that could flow like a stream of water,” he explained.
In June 2017, 16 months after the launch of the project, a continuous polymerization process became operational at our Ulsan plant. This was how our researchers succeeded in developing the world’s first CD PET continuous process.
There were not enough existing technologies to use as reference. The engineers were tasked with developing a technology with no assistance from overseas engineering firms. According to Assistant Team Leader Oh Seung-taek, teamwork made the difference.
“Team Leader Lee Sang-gon, who had a lot of practical experience, was able to come up with a brilliant equipment design. He studied the problem with an open mind, and he was passionately driven. We became confident of success after seeing how he worked,” he said.
Simulation experiments were carried out for months using a setup just like the actual process, made with small models that were 1/100th the size of the actual equipment. Because it was a continuous process, problems that occur during operations could lead to significant losses. To prevent such risks, the simulation experiments were prepared with extreme care. Team Leader Lee Sang-gon also mentioned passion in addition to teamwork.
“Assistant Team Leader Oh dropped by our office as frequently as an Ulsan plant employee to talk with our production line workers. His passion and commitment became infectious to our production workers,” he said.
Working together with people for a common goal on the path toward a new technical innovation has improved productivity by 5 times, reduced costs, and given us much better consistency in quality. The researchers are determined never to stop challenging themselves in their quest to leave a footprint in the path of innovation.
Article | Shin Kyung-Hwa
Photo| Park Hae-joo (Day40 Studio)
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