Nonwoven fabrics have become an increasingly popular choice in various industries. Thanks to their versatility and durability. These fabrics are as used in a wide range of applications, from clothing and bedding to medical supplies and automotive interiors. Nonwoven fabric machines are the backbone of this industry, and they play a crucial role in the production of high-quality nonwoven fabrics.

Simply Saying About Process Of Nonwoven Fabric Machines

Nonwoven fabric machines are as designed to manufacture nonwoven fabrics from different types of fibers. These machines use a unique process that involves bonding fibers together through heat, chemicals, or mechanical means instead of weaving or knitting. The fibers used in nonwoven fabrics can be natural, synthetic, or a blend of both, and they can be of different lengths and thicknesses.

Various Types Of Nonwoven Fabric Machines

Nonwoven fabric machines are available in various types and configurations, depending on the specific requirements of the fabric being produced. Some of the most common types of nonwoven machines include air-laid machines, spunbond machines, meltblown machines, and needle-punch machines.

Air-laid machines

This is the machine that use a process that involves dispersing fibers in the air and then bonding them together with a bonding agent. This process produces a fabric that is soft, absorbent, and durable, making it ideal for use in a wide range of applications, such as hygiene products and medical supplies.

Spunbond machine

Indeed, It use a process that involves extruding molten polymer through a spinneret and then laying the fibersdown on a conveyor belt. These fibers are then bonded together through heat or chemicals to create a fabric that is strong, lightweight, and tear-resistant. Spunbond fabrics are commonly used in industrial applications, such as geotextiles and filtration systems.

Meltblown machines

Actually, they use a process that involves extruding molten polymer through a small nozzle, which creates fine fibers. These fibers are then blown onto a conveyor belt, where they are bonded together through heat or chemicals to create a fabric with excellent filtration capabilities. Meltblown fabrics are commonly used in medical masks and other protective equipment.

Needle-punch machines

They use a process that involves punching fibers through a fabric web to create a fabric with a three-dimensional structure. The fibers are then bonded together through mechanical means, creating a fabric that is strong, durable, and breathable. Needle-punch fabrics are commonly used in automotive interiors and home furnishings.

The non-woven industry is a rapidly expanding industry that has gained significant importance in recent years. The industry has seen a surge in demand for non-woven fabrics due to their versatility, durability, and cost-effectiveness. Non-woven fabrics are used in a wide range of applications such as hygiene products, medical supplies, filtration systems, and many more. Melt blown machine is the backbone of non-woven equipment and are responsible for the high-quality non-woven fabrics that we use in our daily lives.

Explaination Of The Meltblown Machine

Melt blown machines are used to produce meltblown fabrics, which are a type of non-woven fabric that is made using a process called melt blowing. The meltblown process involves the extrusion of a polymer through a small nozzle at high temperatures and pressures, which creates fine fibers that are then blown onto a conveyor belt. The fibers are then bonded together to create a non-woven fabric with unique properties such as high tensile strength, low weight, and excellent filtration capabilities.

The meltblown machine is a complex piece of equipment that requires precision engineering and advanced technology to produce high-quality fabrics. The machine consists of several components, including an extruder, a die, a spinneret, and a quenching system. The extruder is responsible for melting the polymer, which is then pushed through the die to create a uniform flow of molten polymer. The spinneret has small holes that are usedto extrude the molten polymer into fine fibers, which are then cooled and solidified by the quenching system.

The Quality Of The Meltblown Fabric Depends On Several Factors

The quality of the meltblown fabric depends on several factors. It includes the type of polymer used, the temperature and pressure of the extrusion process, and the speed and distance of the fiber spinning. The meltblown machine needs to be carefully calibrated to ensure that these factors are optimized to produce high-quality fabrics.

Melt-Blown Machines With Various Sizes

Melt blown machines are available in various sizes and configurations, depending on the application and production capacity. Small-scale machines are suitable for research and development purposes and can produce a few kilograms of fabric per hour. Large-scale machines, on the other hand, can produce several tons of fabric per day and are used in commercial production facilities.

The demand for melt blown machines has increased significantly in recent years due to the growing demand for non-woven fabrics. The COVID-19 pandemic has further fueled the demand for non-woven fabrics, particularly for the production of face masks, medical gowns, and other protective equipment. As a result, several companies have invested in melt blown machines to meet the growing demand for non-woven fabrics.

PP spunbonded (polypropylene spunbonded) nonwoven fabric is widely used in various industries for its functionality and quality. The pp spunbond nonwoven fabric making machine continuously produces PP spunbond nonwoven fabrics in large quantities.

pp Spunbond Nonwoven Fabric Making Machine

PP spunbond nonwoven fabric is made through a process known as spunbonding. This involves melting polymer filaments and extruding them through tiny spinneret holes into fine fibers. As the fibers exit the spinneret, a flow of air carries the fibers to form a random web on a collection belt.

The pp spunbond nonwoven fabric making machine controls every step of this process with precision to produce consistent fabrics. The main parts of the machine include:

• Filament extruder – Melts and extrudes the PP polymer into fine filaments
• Spinneret – Contains multiple holes that form the filaments into fibers
• Winding unit – Winds up the finished nonwoven fabric for rolling
• Air supply system – Provides airflow to randomly deposit fibers onto the belt

Process By PP Spunbond Nonwoven Fabric Making Machine

During production, the machine heats and feeds the PP pellets into the extruder at a constant rate. The extruder melts the polymer and forces it through the spinneret holes. Hot air blows the fibers onto the moving belt to create a web.

The machine then compacts and consolidates the web through processes like needle punching and thermal bonding. This fuses the fibers together to give the fabric strength and stability.

PP Spunbond Nonwoven Fabric Has Many Applications Thanks To Its Characteristics:

• High strength and durability
• Good moisture absorption
• Superior oil and chemical resistance
• Excellent barrier properties
• Wide range of basis weights

Some Common Uses Of PP Spunbond Nonwoven Include:

• Hygiene products like diapers and feminine pads
• Lawn and garden supplies like weed barrier fabrics
• Filters for air, liquids and gases
• Medical products like drapes and gowns

PP spunbonded nonwoven fabric is made using specialized nonwoven equipment that extrudes and spinstretch polypropylene fibers to create a bonded web. The process involves extruding polypropylene through spinnerets to form continuous filaments, which are then drawn, collected and bonded to form the nonwoven fabric.

PP Spunbond Nonwoven Fabric Making Machine

What is pp spunbonded?

In the spunbonded process, the molten polypropylene is extruded through the spinneret holes to form many continuous filaments. Hot air draws and stretches the filaments to diameters between 5 to 30 microns. The fine filaments are randomly deposited on the collecting belt to form a web.

The calender stack applies heat and pressure to thermally bond the points of filament intersection, giving the web adequate tensile strength and integrity. This bonded nonwoven fabric is then wound onto a core.

Spunbond nonwoven fabric machines

Spunbond nonwoven fabric making machines can produce fabrics with basis weights ranging from 5 to 150 gsm. It depends on the line speed, polymer throughput and number of spinneret holes. The properties of the PP spunbonded fabric like tensile strength, elongation and pore size are determined by factors like:

Filament diameter

Extrusion temperature

Draw ratio and air flow

Calender temperature and pressure

Basis weight

PP spunbonded nonwoven fabrics are widely used in applications like filtration, hygiene products, geotextiles and wipes due to their good strength, spinnability and cost effectiveness.

What Do You Need To Consider For PP Spunbonded Nonwoven?

PP stands for polypropylene, the most common polymer used for spunbonded nonwovens due to its properties and cost.

Spunbonded refers to the process of spinning continuous filaments and bonding them into a fabric. This contrasts with meltblown and needlepunching.

The continuous filaments produced by spunbonding are typically 5 to 30 microns in diameter. This is larger than meltblown fibers but provides good strength.

Compared with the ordered structure of woven or knitted fabrics, spunbond PP nonwovens have a random, entangled network structure.

Meltblown nonwoven fabric is made using a meltblown machine that extrudes specialized thermoplastic polymers through tiny nozzles to produce extremely fine fibers. These meltblown fibers are randomly deposited and bonded together to create an insulating material with many unique properties.

Meltblown Machine Nonwoven Fabric

A meltblown machine uses high-velocity air to draw and attenuate extruded thermoplastic material into fine fibers with diameters typically between 0.5 to 15 microns. The fine fibers are randomly deposited on a forming surface to create a web of entangled fibers that constitutes the nonwoven fabric.

Meltblown nonwoven fabric is widely used as a filter or barrier material due to its small fiber structure, high surface area, and porosity. It is commonly made from polymers like polypropylene and polyester.

Nonwoven Fabric Produce By Meltblown Make Machine

The meltblown process can produce webs with basis weights between 5 to 300+ gsm through melt blown machine. Actually, It depends on the production settings and end use of the nonwoven material. Fabric properties like density, pore size distribution, stiffness and tensile strength are determined by factors like the polymer used, extrusion temperature, air flow, throughput rate and more.

A meltblown make machine or line consists of several components:

• An extruder to melt and feed the thermoplastic material
• Slot die nozzles that extrude the molten polymer
• High-temperature heated air blowers that draw and attenuate the extruded material into fibers
• A forming surface where the fibers are collected
• A collection bed and winding system
• An oven or treatment unit to thermally bond the fibers together
• Various rolls and tensioners to control the web movement

4 Key Challenges In Producing High-quality Meltblown Nonwovens Fabric

• The meltblowing process needs to extrude the polymer at a precise and uniform rate to achieve consistent fiber diameter and basis weight. Any fluctuations can cause nonuniformity in the resulting fabric.
• The fiber diameter has a major influence on fabric properties like pore size and density. Precisely controlling the air flow and extrusion variables is required to maintain a narrow fiber diameter distribution.
• Short bursts of thicker fibers, known as “shot noise”, can occur sporadically during meltblowing. This creates areas of nonuniform basis weight and needs to be minimized.
• The small nozzles in the die head are prone to clogging, especially with fillers and additives in the polymer. Frequent cleaning and monitoring is required to maintain consistent fiber formation

Melt-blown PP is polypropylene melt-blown special material, which is based on polypropylene as raw material, adding various additives, using the method of controlled rheology to improve the fluidity and molecular weight distribution of resin, the modified polypropylene melt mass flow rate can reach more than 1500, and low ash, long spinning cycle, comprehensive stable performance, suitable for melt-blown non-woven fabric forming process.

It is the main raw material for the production of polypropylene melt-blown non-woven products. Real melt-blown materials can be degraded, and the 2040 common on the market is just ordinary PP materials. Real PP melt-blown materials are all modified. The quality of the small machine itself is a big part of the reason. For regular melt-blown cloth, it is necessary to use 1500 melting finger special melt-blown material, add the tret master particle and the tret process to further improve the filtering efficiency.

The manufacture of masks cannot do without spunstick cloth and melt-blown cloth, both of which are high melting finger PP materials after degradation. The higher the melting index of PP used to make melt-blown cloth, the finer the fiber will be melted out, and the better the filter performance of the melt-blown cloth will be. And PP with low molecular weight and narrow molecular weight distribution is easier to make fiber with good uniformity.

The raw material for the production of mask S layer (spunbond cloth) is mainly high melting finger PP with melting index between 35 and 40, while the production of M layer (meltblown cloth) is meltblown grade PP with higher melting index (1500).

The production of these two kinds of high melting finger PP is inseparable from a key raw material is the organic peroxide depressant, due to the general PP melting index is generally low, poor liquidity in the melting state, limited its application in some fields, by adding organic peroxide to modify polypropylene, can improve the melting index of PP, reduce its molecular weight, Moreover, the molecular weight distribution of PP is narrowed, so that it has better fluidity and higher drawing rate. Therefore, PP modified by organic peroxide degradation can be widely used in the field of thin-wall injection molding and non-woven fabric.