A spunmelt nonwoven machine as used to produce various nonwoven materials including hygiene products, filtration media, and apparel fabrics. A common type of spunmelt machine is the polypropylene (PP) single-step sandwich meltblown spunmelt machine (SSMMS), which produces combined spunbond and meltblown webs in a single process. This PP SSMMS spunmelt machine offer high performance and yield for nonwoven manufacturers.

Introduce about PP SSMMS spunmelt machine

In a PP SSMMS spunmelt machine, polymer granules like polypropylene are first fed into a hopper and conveyed into the extruder. Inside the extruder, the polymers are melted and forced through a spinneret. The spinneret contains many tiny holes that create continuous polymer filaments as they exit.

As the molten filaments exit the spinneret, they are drawn vertically by a godet system where they are cooled by air. As the filaments harden, they become thinner and more stable, forming continuous fibers. These fibers then pass through the sandwiching area where hot air to form the meltblown layer is injected in between the spunbond layers.

The sandwiching area is a key feature of single-step SSMMS machines. In this section, the spunbond fibers pass between an upper and lower conveyor, with hot air blown from nozzles in between to create the meltblown layer. The amount of hot air, air pressure and nozzle arrangement determine the basis weight and thickness of the meltblown layer.

After sandwiching, the combined web consisting of spunbond and meltblown layers passes over a roller bed and into an oven for annealing and further cooling. The annealed composite web is then wound onto a take-up roller.

The key advantages of PP SSMMS machines include:

• High production rates – Up to 800 kg/hr of nonwoven material can be produced.
• Width flexibility – Web widths from 1.2 to 4.5 meters are possible, depending on the machine.
• Better control of layer ratios – The combination ratio of spunbond to meltblown layers
  can be precisely set from 20/80 to 80/20.
• Uniform web weights – Precise control of spinning, air flow and winding ensure consistent
  basis weights within +/- 3%.
• Superior quality and performance – The integrated process produces composite webs with
  bonding between layers for improved strength, barrier properties and filtration.

PP SSMMS machines also require less space and capital investment compared to traditional two-step systems that produce spunbond and meltblown layers separately and laminate them later. However, the single-step process does involve more complex control of the sandwiching section.

When selecting a PP SSMMS spunmelt machine, manufacturers should consider factors like web width, production rate, layer ratio flexibility, Energy efficiency, technical support and maintenance requirements. Machine suppliers often offer custom configurations and options to meet the specific application needs for products like diapers, wipes, filters and geotextiles.

Nonwoven fabrics are essential materials used in everything from diapers and medical fabrics to geotextiles and automotive applications. As demand rises, manufacturers are seeking out the latest technology in spunbond nonwoven fabric make machine to improve productivity and product performance.

What Is Spunbond Fabric And How Is it Made?

Spunbond or spunbonded fabrics are a popular type of nonwoven made from extruded, spun filaments bonded together to form strong, durable webs. The spunbond process starts with polymer resin pellets fed into an extruder where they are melted at high temperatures into a polymer solution.

The molten polymer is pumped into a spinneret block featuring hundreds of tiny nozzles that spin the polymer into fine continuous filaments as they are extruded. Cooling air blows onto the filaments as they are spun to solidify them.

The filaments are drawn onto a conveyor belt where they are deposited in random orientations to form a web. This web then passes through heated calender rollers that bond the intersecting fibers together through a combination of mechanical entanglement and thermal fusion.

The final spunbond fabric is wound into rolls to be further finished or converted into end products. Variations in polymers, production parameters, and bonding methods yield spunbond materials with unique properties for different applications.

Benefits Of Advanced Spunbond Nonwoven Machines

Spunbond nonwoven manufacturing has come a long way from early belt-based processes developed in the 1970s. Today’s state-of-the-art spunbond lines offer major advantages like:

• Higher speeds and throughput – Modern spunbond lines can run at speeds exceeding 1000m/min to maximize production.
• Superior web uniformity – Advanced metering pumps, spinnerets, and other features improve weight and thickness consistency.
• Finer filaments – Filaments down to 1 micron in diameter produce smoother, finer fabrics.
• Composite fabrics – Some systems can produce SMS, SSMMS, and other composite structures.
• Better energy efficiency – Optimized process controls reduce power consumption.
• Reduced downtime – Equipment designed for quick changeovers, maintenance, and expanded production windows.
• Improved end product quality – Tighter process control, versatile polymer options, and better web bonding lead to higher performing fabrics.
• Smart monitoring – IoT integration and data analytics help identify process optimization opportunities.

These capabilities allow manufacturers to gain a competitive edge with their spunbond nonwovens.

Key Spunbond Line Components And Technologies

Some noteworthy components and technologies available on state-of-the-art spunbond lines include:

• High-speed, high-output extruders – Gala underwater pelletizers offer precision polymer melting and delivery.
• Advanced metering pumps – Accurate polymer filtering, pressure regulation, and flow control.
• High hole density spinnerets – Up to 8000 holes produce more filaments and finer webs.
• Optimized quenching – Strategically placed cooling systems solidify and draw filaments consistently.
• Web handling systems – Vacuum devices and electrostatic pinning smoothly convey the spunbond web.
• Multibeam thermal bonders – Computer-controlled bonding achieves precise caliper, tensile strength, and softness.
• Surface treatment – Corona, plasma, or flame treatment allows better printing, lamination, and liquid absorption.
• Quality control systems – Auto gauging, sampling, and defect detection ensure consistent output.
• Remote monitoring and control – IoT systems enable data-driven optimization and predictive maintenance.
• With such features, manufacturers can create high-performing spunbond materials to meet any specifications.

Partner With A Leading Spunbond Line Manufacturer

As a premier maker of turnkey spunbond, meltblown, and composites lines for over 20 years, XYZ Machinery is an ideal partner for your next spunbond project. Our extensive expertise in engineering tailored spunbond solutions includes:

• 3D modeling of custom configurations
• Precision manufacturing of equipment
• Turnkey line installation and optimization
• Local after-sales service and support
• Operator training and maintenance

Whether you need a complete greenfield installation, upgraded line components, or a debottlenecking of your existing process, XYZ Machinery has the capabilities and experience to deliver maximum performance and value.

Meltblown nonwoven fabric machines use high-speed hot air to produce light, porous fabrics made of extremely fine fibers. These machines have many applications in industries like healthcare, filtration and apparel.

What Is A Meltblown Nonwoven Machine?

A meltblown nonwoven machine is a special type of extrusion equipment used to manufacture meltblown machine nonwoven fabric. It works by extruding thermoplastic resins through fine nozzles and blowing heated air at high velocities onto the extruded filaments.

As the filaments exit the nozzles, the hot air attenuates and entangles them, forming a web of fine fibers that is collected on a conveyor. The resulting nonwoven fabric is lightweight with very small fiber diameters.

Meltblown machines typically have three main components:

• Extruder – Melts the thermoplastic resin pellets or granules and extrudes it through nozzles.
• Distribution plate with nozzles – The melt is forced through thousands of tiny nozzles to form the filaments.
• Hot air system – High-velocity air heats up as it passes over a chamber and is then blown onto the extruded filaments.

The hot air stretches and attensuates the filaments as they exit the nozzles, forming fine fibers that quickly mix and entangle on a rotating forming surface. The nonwoven web is then conveyed to a winding unit.

Key Parameters of Meltblown Machines

• Nozzle holes – The number and diameter of nozzle holes determine the fineness of the fibers and fabric basis weight.
• Air temperature – Higher air temperatures produce finer fibers but can damage the resin.
• Airflow – Higher air velocity produces finer fibers but consumes more energy.
• Resin type – Different resins like PP, PE and PET are used based on fabric properties required.
• Production speed – Higher speeds allow more fabric production but affect fiber fineness.
• Width – Machine width determines the size of the nonwoven fabric produced.

Machine manufacturers optimize these parameters to produce meltblown fabrics with the properties required for specific end uses. Wider machines with more nozzle holes can produce higher output.

Applications of Meltblown Nonwoven Fabrics

Attributes of meltblown nonwoven fabrics that enable various applications:

• The fine fiber diameter produces high porosity and surface area.
• They are light due to weighing between 10 to 300 gsm.
• The fabrics exhibit good barrier properties against microbes, liquids and particles.

Common uses of meltblown nonwoven fabrics:

• Healthcare: They are used in surgical drapes, gowns, masks and swabs.
• Filtration: They serve as filter media for air, liquids and other applications.
• Apparel: They are used as interlinings and insulation layers in clothing.
• Wipes: They are used to make wet wipes for personal and industrial cleaning.
• Acoustics: They are used as sound insulation in buildings and vehicles.