Melt-Blown-Fabric

Some Know-hows of Meltblown Fabric Production

The manufacturing of meltblown fabric production equipment is not complicated, and the main problem that needs to be overcome is the process. Because the parameters of temperature, air pressure, mold, and speed are involved, it needs continuous running and debugging to achieve the best results.

How to Increase the Strength

  1. Increase the hot air flow (fine fibers, many winding nodes, uniform fiber stress, increased strength, but after a certain degree, it will decline)
  2. Raise the temperature of hot air (same as above);
  3. Appropriately increase the weight of the product (within the range of internal control);
  4. Raise the temperature of the die head (die tip) and other areas (same as a);
  5. Appropriately reduce output;
  6. Appropriately reduce the DCD (not too small, but the brittle strength will decrease, combined with other parameters);
  7. Increase the suction at the bottom of the net (large grammage is more obvious);
  8. Use raw materials with low melt flow index.

How to Increase Elongation

  1. Appropriately reduce the hot air flow or temperature (the slippage path of the node becomes larger and the feel becomes harder);
  2. Reduce the working temperature of the die head (die tip) (same as above);
  3. Appropriately reduce the output;
  4. Increase the DCD (more effective when used in conjunction with a or b);
  5. Reduce the ambient temperature (spinning ambient temperature);
  6. Increase the suction of the bottom of the net (the effect is not obvious, the large grammage is better);
  7. Change the fiber angle (change the structure of the fiber mesh, not commonly used)
  8. Properly increase the output (this method will cause the reduction of other physical indicators, not commonly used).

How to Reduce Resistance

  1. Reduce the hot air flow or temperature (fiber becomes thicker, the porosity is larger, the resistance is small, and the efficiency becomes worse);
  2. Increase DCD (increasing the bulkiness of the fiber, the porosity is large, and the efficiency becomes poor);
  3. Reduce the spinning environment temperature (the fiber is cooled sufficiently, the structure is fluffy, the porosity is increased, and the hot air can achieve the purpose of reducing resistance and improving efficiency);
  4. Reduce the suction at the bottom of the mesh (the fiber changes from dense to fluffy, the porosity becomes larger, and the large grammage is more obvious);
  5. Reduce the working temperature of the heating area such as the die head (die tip) (the fiber becomes thicker and the porosity becomes larger);
  6. Increase the metering pump (the extrusion volume becomes larger, the fiber becomes thicker, the porosity increases, and it is generally used when the order is transferred quickly);
  7. Appropriately reduce the weight (within the range of internal control).

How to Improve Filtration Efficiency

  1. Increase the hot air flow or temperature (increasing the fineness of the fiber, reducing the porosity, improving the catching ability, but the resistance increases);
  2. Increase the electrostatic voltage (current) (polarized fiber, increase the electrostatic field energy of the fiber and improve its adsorption capacity);
  3. Add powder or other electrets to the raw materials (improve the fiber’s power receiving capacity and storage time, let the fiber carry more charge and charge time);
  4. Increase the suction at the bottom of the net (increasing the density of the fiber and improving the catching ability of the fiber. The large grammage is obvious and not commonly used);
  5. Properly reduce the output (under the same process, the extrusion volume becomes smaller, the fiber becomes thinner, and the resistance increases);
  6. Raise the working temperature of the die head (die tip) and other areas (melt fluidity becomes better, fibers become thinner);
  7. Increase the spinning ambient temperature (fibers become thinner, generally when the room temperature increases, the resistance increases significantly, and other physical indicators decrease);
  8. Properly increase the amount of powder added.

How to Both Reduce Resistance and Improve Efficiency

  1. While increasing the DCD, increase the hot air flow or temperature appropriately and reduce the bottom suction (increasing the fineness and bulkiness of the fiber);
  2. Improve the fiber fineness and reduce the spinning ambient temperature (such as adding cold air device);
  3. While increasing the bulkiness of the fiber, increase the electrostatic voltage (current), and appropriately increase the amount of powder added;
  4. Improve the fineness of the fiber and reduce the weight (not commonly used).

How to Improve Both Strength and Elongation

  1. Properly reduce the hot air flow or temperature, reduce the DCD, and appropriately increase the bottom suction (used for the physical temperature is too high and the raw material melting index is too high to cause physical indicators to fail);
  2. Properly increase the flow or temperature of the hot air, increase the DCD, and appropriately reduce the air suction at the bottom of the net (used to be unqualified due to too low ambient temperature and too low raw material melting index);
  3. Reduce output;
  4. Increasing the fineness of the fiber while reducing the spinning ambient temperature.

How to Reduce Product CV Value

  1. Correspondingly change the working temperature of each area of the die head (the temperature is increased if the gram weight is small, and vice versa);
  2. When the local efficiency and resistance conflict with the CV value, a baffle can be added to the position (increasing the local spinning ambient temperature);
  3. The CV value of longitudinal grammage is mainly related to the stability of the speed of the web-forming system.

Why Shot happens?

  1. Improper setting of working temperature (too high or too low, generally too high is easy to appear);
  2. The raw material or masterbatch is too dirty (generally the whole cloth surface, or appear in a large area);
  3. After the die head is used, the die tip is dirty (sometimes it is a poor thread or a large area appears, you can use a scraper to scrape the die tip);
  4. There are carbonized substances or dirty plugs around the die tip that cause poor wire output (usually caused by abnormal shutdown. Generally, a small amount occurs locally, which can be solved by scraping the die tip);
  5. The air knife is partially dirty or has physical damage to the air knife (affecting the uniformity of the normal spinning airflow, which appears locally and is accompanied by longitudinal thin grooves);
  6. The output is too high or too low (generally appears in large areas, reduce or increase the output to solve);
  7. Raw material melting index is too high or too low (usually too high is easy to appear);
  8. There is water in the raw materials.

Reasons for Flying Flowers

  1. The hot air flow is too large or the temperature is too high (too many broken fibers);
  2. The working temperature in each area is too high (too many fiber breaks);
  3. The DCD is too small (the cloth is too dense, which affects the suction efficiency);
  4. The spinning environment temperature is too high (same as a);
  5. When adding recycled materials, the amount of recycling is too large.
  6. The output is too low;
  7. Improper setting of the suction parameters of the bottom of the net or the screen is too dirty (small suction, the fiber cannot be fully absorbed on the screen and detached from the screen);
  8. The raw material melting index is too high.

Leave us a comment below for a further discussion or contact us for further clarification.

This post was firstly published on September 6, 2021.
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