In recent years, the demand for spunbond and meltblown nonwovens has grown faster and faster. Meltblown nonwovens are hard to come by in 2020. Because it is the main material of medical masks. Do you know how non-woven machines produce spunbond and meltblown nonwovens? They are similar in most processes, but very different when it comes to fiber drawing. So the structure and properties of fibers and fabrics are completely different. Spunbond and meltblown processes are sometimes combined for specific applications. For example, surgical gowns and diapers require SMS fabrics. Let's take a look at the production process of the non-woven machine.
Both polyester and polypropylene are ideal raw materials for making nonwovens. Polyester has higher requirements for non-woven machines. Whereas polypropylene is suitable for all nonwoven machines.
Polyester is widely used in the production of spunbond or meltblown nonwovens. Its fabric is strong, lightweight, dyeable, and wrinkle-resistant. It also has good washability. Polyester is extracted from petrochemical resources. So not expensive.
Polypropylene is white and semi-crystalline. It usually comes in the form of chips or granules. Polypropylene has become a major material when it was first used in the nonwoven field in the 1970s. Polypropylene has become a very important industrial and household fiber. But it has less of an impact on the apparel industry. Because people don't like its waxy feel. Its dyeability is also not outstanding. In the chemical industry, polypropylene nonwovens have grown rapidly in recent years. They are used as filter cloths for wet filtration. Industrial applications also include medical and surgical disposables.
Non-woven manufacturing process
Spunbond and meltblown are the most common methods for producing polymer nonwovens. This is a melting and spinning process.
The raw material PP enters the metering equipment
The dosing equipment consists of the main material tank, two batching tanks, a mixing tank, and a suction device. The main ingredients and ingredients can be prepared in a certain proportion. They are transported from the ground to the third floor by automated equipment
Extrusion of raw materials into a melt
When the PP chips and additives arrive, the extruder begins to melt. This unit has 8 heating zones. The standard dimensions of the female thread are φ135 mm, φ150 mm, and φ170 mm. The speed range is 20 to 80 r/min. The maximum extrusion rate is 450kg/h.
Extrusion of recycled nonwoven into melt
The recycled scrap is extruded into a melt through a recycling extruder. The structure is the same as the main extruder. It has 4 heating zones. The internal thread size is φ105 mm.
Filtration of impurities in the melt
There are impurities in the melt flowing out of the extruder. To keep the melt clean, we use vertical filters to remove impurities. Actually, there are two filters in this device. Each filter works independently. When one filter gets dirty, just turn the steering wheel and the other filter will work in place of the previous one. It does not need to shut down the entire non-woven machine.
Control the feed rate of the melt stream
To work smoothly, a spin pump is used to control the supply speed. It ranges from 200cc, 250cc, and 300cc with corresponding cloth widths of 1600mm, 2400mm, and 3200mm.
The melt in the spinning pump flows to the spinning box. The filaments are blown out through a spinneret. There are thousands of holes in the spinneret. Size from Φ0.2mm to Φ0.6mm.
Spunbond and meltblown are completely different in drawing filaments.
The quench air duct supplies conditioned air to cool the filaments of the spinneret. It is located below the spinneret plate. The filaments are drawn into elongated fibers as they cool. The device includes a pull-up channel, a pull-down channel, and a diffusion channel.
The melt blowing method uses a high-speed hot air flow to rapidly draw the melt into filaments. This fiber is short and thin. The process is simpler than spunbond but less durable.
Form a mesh
Fibers are divided into bundles of many filaments. They lie on the net to form a net. The web forming machine includes a web forming belt drive system, a suction channel device, a sealing device, and the like.
The webs are thermally and mechanically bonded. Then perform special online processing, such as calendar processing.
Air cut non-woven fabric
Winders are used to winding fabrics on rolls. It includes two flat rollers and two pneumatic rollers. Using the cutting machine, the fabric can be cut to the desired width.
Now you should know how to make nonwovens. I hope it will be helpful for you to choose a non-woven production line. We specialize in the production of non-woven machines, please feel free to contact us if you need it.
AZX is a professional non-woven machine manufacturer. We specialize in producing S (spunbond), M (meltblown), SS, SXS, SSS, SMS, SSMS, SMMS, SMMMS, SSMMS, etc. In order to meet the needs of different customers, we not only provide trailer accessories for existing models but also do OEM and customized products. If you can't find the product you need on the website, please contact us and we can work with you to design and produce a product that suits your needs.