I. Application

This equipment is suitable for the production of spunbond nonwovens with a variety of colors and different properties using PP chips as main material mixed with master batch, antioxigen, anti-pilling agent and flame retardant.

II. Design Basis 1.Project data

Raw material: Polypropylene chips (Melt index: 30-40g/10min, with variation not more than 1% for each batch; Melt point: 166°C; Ash content: <0.15-0.25%)

Annual output: 3000 tons (say 7,200hours based on GSM over 30)

Extruder size: φ170×30

Max. winding diameter: 1000mm

Process speed: 10-130m/min

Installed power: approx. 1100kW

1.Product specifications:

Web width: 3200mm

Single filament titer: 1.8-2.5 denier

Web weight: 10-150g/m2

III. Process flow

Feeding (suction, dosing and mixing)→melting and extruding (with recycle extruder)→filtering→metering→spinning→quenching→air drawing→forming→calendering→winding→slitting

Description of unit machines

1. Dosing and mixing system

1.1 Function

Chips are transported by a suction system from the ground to the dosing and mixing system on the third floor. Main material and auxiliary materials can be prepared as per a certain ratio. The whole system consists of the following:

Consisting of a main material tank, two auxiliary tanks, a mixing tank, a suction device, a metal detector, complete with an alarm unit for low and high chip levels, automatic control of feeding.

The main material is suctioned automatically with the ancillary material filled manually. Dosing screws are used for filling proportionally.

1.2 Technical data

Max. feeding capacity for main material: 700kg/hr

Volume of storage hopper: 0.6m3

Max. mixed components: 3

2. Extruder

2.1 Function

Used to melt and extrude PP chips mixed with master batches and additives such as antioxidant, anti-pilling agent and flame retardant agent, including chip inlet, automatic temperature controls, cooling system, alarm system for all the heating zones with temperature meter, solid relay and Pt100 platinum resistance.

2.2 Technical data

Max. extruding capacity: 700kg/hr

Diameter of screw: 170mm

L/D: 30

No. of heating zones: 7

3. Spinning machine,

3.1 Function

The melt coming from the extruder becomes filaments after passing through the filter, melt distribution line, metering pump and spin packs. It also includes automatic heating and insulating system, pressure indication and control system behind filtering screen.

3.2 Technical data

3.2.1 Single filament titer: 1.8-2.5 denier

Web weight: 10-150 g/m2

3.2.2 Melt prefilter

Filtering precision: 60μm

3.2.3 Metering pump and its drive

Metering capacity: 300cm3/r

Driven by an inverter-controlled synchronous motor

3.2.4 Spinning beam

With electrical heating

No. of heating zones: 23

3.2.5 Melt distribution line

With electrical heating

3.2.6 Spin pack

Hole diameter:Φ0.5mm

L/D ratio:5

Material for spinneret and distribution plate: heat-resistance SS

3.2.7 Monomer suction device

Driving power: 2.2kW

4 Edge recycle extruder

4.1 Function

Used for recovery of edges, including A.C. regulating motor for recovery screw and complete temperature control system composed by temperature meter for each heating zone, solid relay and Pt100 platinum resistance.

4.2 Technical data

Screw size: φ120 x 20

5 Quenching and drawing system

5.1 Function

Used for the cooling and drawing of filaments, including a quenching chamber, upper drawing channel, middle drawing channel, lower drawing channel, and diffusion air duct. Double-side quenching is employed.

5.2 Technical data

Nominal working width: 3200mm

6 Web former

6.1 Function

Used as carrier for the drawn fiber webs, including a drive system for web forming belt, a suction channel device, a sealing device, an automatic correcting device, belt tensioning device, a frame and a pre-pressing roller

6.2 Technical data

Max. mechanical speed: 150m/min

Process speed: 12-130m/min

Air permeating ratio for web forming belt: 7000-8000m3/h.m2

7 Calender

7.1 Function

Used for bonding formed webs by pressure and heating.

7.2 Technical data

Process speed: 10-130m/min

Working width: 3600mm

Type of rollers: engraved upper roller and plain lower roller

8 Winder

8.1 Function

Used for winding the bonded webs on rolls

8.2 Technical data

Process speed: 10-130m/min

Working width: 3600mm

Max. winding diameter: 1000mm

9 Slitter

9.1 Function

Used for cutting wound rolls

9.2 Technical data

Mechanical speed: 10-300m/min

Working width: 3600mm

Minimum splitting width: 200 mm

Max. roll diameter: 800mm

10. Electrical Control

10.1 Controlled by SIEMENS PLC and touch screen.

10.2 Inverters to be Siemens