Spun bond and melt blown nonwovens have an increasing growth in recent years. Melt blown non woven is hard to purchase in the year 2020. Because it’s the main material of medical face masks. Do you know how nonwoven machine manufactures spunbond and meltblown nonwoven ? They are similar in most processes, but very different in fiber strectching. So the structure and properties of the fibers and fabrics are totally different. Processes of Spun bond and melt blown are sometimes combined for a particular application . For examaple, surgical clothes and diapers request SMS fabric. Let’s take a look at the production process of non woven machine.

Raw material

Both polyester and polypropylene are ideal raw material for nonwoven making. Polyester has a higher request for nonwoven machine. While polypropylene is workable for all nonwoven machines.

Polyester is widely used in spun bond or meltblown nonwoven production. Its fabric is strong, lightweight, dyeable and wrinkleless. It also has property of good wash wear. Polyester is extracted from petrochemical sources. So it’s inexpensive.

Polypropylene is in white color and semi-crystalline. It usually appears as chips or granules. Polypropylene has become the main material when it was first used in nonwoven area in the 1970’s. Polypropylene has made itself as a very crucial industrial and household fiber. But it performs less impact in the apparel sector. Because people don’t like its waxy hand feel. It’s also not outstanding in dyeability. In the chemical industries, Polypropylene nonwovens have a sharp increase in recent years. They are used as filter fabric for wet filtration. Industrial applications also include medical and surgical disposables.

nonwoven machine manufacturing process diagram

Nonwoven manufacturing process

Spun bond and melt blown are the most common methods to produce polymer-laid nonwoven fabrics. This is a process of melting and spinning.

Raw material PP comes into dosing equipment

Dosing equipment consists of a main material tank, two ingredient tanks, a mixing tank and a suction device. Main material and ingredients can be prepared as per a certain ratio. They transports from ground to the third floor by automatic equipments

Extruding raw material into melt

Extruder machine starts melting when PP chips and additives arrive. This machine has 8 heating zones. Standard sizes of the inside screw are φ135 mm, φ150 mm and φ170 mm. Rotary speed ranges from 20 to 80 r/min. The max extruding capacity is 450kg/h.

Extruding recycle nonwoven into melt

Recovery scrap is extruded into melt by recycle extruder machine. The structure is same as main extruder. It has 4 heating zones. The inside screw size is φ105 mm.

Filter impurities from the melt

There are impurities in the melt when it outflows from extruder machine. In order to make the melt clean, we use vertical filter to remove the impurities. In fact, there are two filters in this device. Each filter works independently. When one filter becomes dirty, just turn the steering wheel, then the other filter works instead of the previous one. It doesn’t need to power off the whole nonwoven machine.

Control the supply speed of melt flow

In order to work smoothly, spin pump is used to control the supply speed. It ranges from 200cc,250cc and 300cc with corresponding cloth width 1600mm,2400mm and 3200mm.

Spinning system

The melt in spin pump flows to the spinning box. Filaments are blown out through spinneret plate. There are thousands of holes on the spinneret. The sizes are from Φ0.2mm to Φ0.6mm.

Filaments stretching system

Spun bond and melt blown are totally different in stretching filament.

Spunbond stretching

The quench air ducts supply the conditioned air to cool the filaments from the spinneret. It’s located below the spinneret block. Filaments are stretched into long and thin fiber when they cool down. This equipment includes upper drawing channel, lower drawing channel, and diffusion channel.

Meltblown stretching

Melt-blowing method uses high-speed heat airflow to rapidly stretch the melt into filaments. This fiber is short and thin. The process flow is more simple than spun bond, but less durable.

 Forming web

Fibers are separated into bundles of many filaments. They lay down on a net to form a web. The web former includes a drive system for web forming belt, a suction channel device, a sealing device, and so on.

Calendar

The web is then bonded thermally and mechanically. Then perform special in-line processing such as calendar processing.

Wind and cut nonwoven fabric

Winder machine is used for winding the fabric on rolls. It includes two plain rolls and two pneumatic rolls. With cutting machine, fabric can be cut into the required width.

Now you should know how to make nonwoven. Hope it will do you some help when purchasing nonwoven production line. But how to judge the quality of nonwoven machine? Be frank, it’s not as easy as other goods. Because this is a huge production line composed of many machines. Here is a simple way. Just check the quality of nonwoven fabric manufactured by nonwoven machine.

How to distinguish the quality of non-woven fabric

How to distinguish the quality of non-woven fabric? Do you know the way to identify the quality when nonwoven machines produce fabrics ? I will introduce you some tips as below.

Seeing

Select a random sample of 2 meter nonwoven fabric. Inspect the surface toward the light for any disqualified signs such as broken fibers or lumps. Observe if the cloth surface is shiny. Then spread the non-woven fabric on a flat ground. The non-woven fabric with good uniformity has no undulations.

Hand feel

Hand feeling is another simple but efficient way to identify the quality of nonwoven fabrics. The good cloth is soft and close to the real knitted fabric. The general fabric is relatively hard. It has a poor hand feel.

Exposure to the sun

Expose it to the sun for one week If time allows. There will be obvious changes after 7 days. Poor quality non-woven fabrics cannot withstand the ultraviolet rays of the sun. It’s as easy as paper to tear by hand.

nonwoven fabric multi colors

Testing

The most precise method is to test the nonwoven fabric by equipment. Below four organizations are commonly recognized in the nonwoven industry.

The first one is Nonwoven Standard procedures (NWSP)

The Second is ASTM – American Society for Testing and Materials

The third one is TAPPI – Technical Association of the Pulp and Paper Industry

The last one is AATCC – Association of Textile, Apparel, and Materials Professionals

We usually test nonwoven fabric in four aspects.

Burst Strength

Air permeability is the rate of air flow when passing through the fixed area of nonwoven. Air will naturally migrate towards the area of lower pressure. The resulting air flow determines the air permeability.

Air Permeability

Elongation is the amount of warp when nonwoven situates under stress. The testing procedures contain a grab strength test. The nonwoven sample is clamped in the tensile testing machine. Elongation impacts the physical performance of the cloth. Products require the ability to contract and expand. With good stretching, deformation fabric can return to its original form.

Elongation

Elongation is the amount of warp when nonwoven situates under stress. The testing procedures contain a grab strength test. The nonwoven sample is clamped in the tensile testing machine. Elongation impacts the physical performance of the cloth. Products require the ability to contract and expand. With good stretching, deformation fabric can return to its original form.

Tear Strength

Tear strength is the amount of force to rip a nonwoven. The test method uses a specialized piece of equipment to create a force to further tears the slit. The tear strength of a nonwoven determines its application. This is a major characteristic to ensure the final product to withstand the stresses from external environment.

I am sure you now have a further understanding of nonwoven machine. As we know nonwoven production lines differ in quality. That is why I want to inform you nonwoven machine working process. As 13 years of machine manufacturing has taught us never to compromise with quality, profession and credibility. What’s more, we offer our customers a delviery guide in the year 2021. It’s worthy your reading.

Leave a Reply

Your email address will not be published. Required fields are marked *