Equipment and Process:
For a comprehensive description of the conventional processes for man-made fiber manufacturing, including the Melt Spun Process, please visit the link to the American Fiber Manufacturers Association (AFMA) website: www.afma.org/f-tutor/techpag.htm.

Fiber Science, Inc. is able to change the machinery and spin pack design as required to best process various polymers. This technology is reflected in a machine design which optimizes the shear and the residence time of the polymer. The spinneret is chosen and the pack screen filter is constructed for the characteristics of the polymer being processed. We have components which allow filtration down to 5 microns if needed. Orifice configurations include round, delta and trilobal orifices. A selection of orifice diameters and orifice numbers is available generating from 1 to 4 threadlines.

A desiccant dryer removes excess moisture from the polymer chips if needed. A nitrogen or argon gas purge is available at the extruder throat.

The extruder is a device that melts and pressurizes the polymer, generally introduced as pellets. Temperature control is achieved through heated barrel zones. No active barrel cooling is provided. The screw is a conventional general purpose design. Mixing sections can be provided. The screw can be quickly removed from the machine for cleaning or replacement.

The extruder feeds an electrically heated steel block surrounded by an aluminum jacket. Uniform heat distribution is designed into the configuration which surrounds the polymer pump. The pump is directly driven and provided with shear pin overload protection.

The quench air system is cross flow air flow. The air is cooled with a chilled water system for precise temperature and air velocity control. A kiss roll is used to lay a topical applicant to the yarn. Finish oil provides filament-to-filament cohesion, lubricity and static discharge to the yarn. The system controls finish oil temperature, and the recirculation of the finish oil.

Godets (rolls or capstans) are induction heated and capable of 2,000 meter per minute operation. The maximum godet temperature is about 200ºC. Various winders can be used, depending on the take-up speed and the number of thread-lines.

The extrusion systems are generally capable of processing about 50 pounds per hour of polymer. Of course, the denier and yarn characteristics ultimately dictate the process throughput.

Processes have been developed for polymers otherwise considered difficult to convert, and for more conventional polymers with enhanced physical properties. Although most efforts go into the manufacture of continuous filament (CF) yarn, the system can produce fibers capable of being crimped and/or cut for staple fiber applications.