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What is benefits of meltblown production line?

Melt-blown method is a method of direct polymer web forming. It is a method of extruding a polymer melt extruded by a screw extruder to extrude the melt stream by extreme high-speed and high-temperature air flow or other means. Very fine fibers are formed, and then gathered on a web forming drum or screen curtain to form a web. Finally, they are reinforced by self-adhesion to produce a meltblown fiber non-woven fabric.

 

What is meltblown production line?

Melt-blown non-woven production line makes use of synthetic high polymer as materials, through melting and spining, the materials forms fiber web directly, and produces unique performance non-woven fabrics. The melt-blown fabric is widely applied to filtration material, padding material, medicine material and wiping materials.

 

entire meltblown equipment consists of the host, heating system, lubrication system, hydraulic system, meltblown spinneret, cooling system, electrical control system, high-pressure fan, network system, electrostatic electret, etc.

 

The main machine is mainly composed of feeding system, screw extruder, filtering device, metering pump, melt-blowing die assembly, receiving device and winding mechanism. When producing meltblown nonwoven materials such as polyester and polyamide, chip drying and pre-crystallization are also required.

 

What is meltblown used for?

Non-woven fabrics are used in a variety of applications, creating products that are used in agricultural, automotive, construction, personal hygiene, roofing, carpeting, upholstery, and medical products, to name just a few examples. Specific examples of the types of products that can be fabricated using non-woven fiber include:

 

  • Filtration, such as HEPA air filters or liquid and gas filter products
  • Masks and respirators for medical and industrial use
  • Disposable medical garbs, such as gowns, drapes, shoe coverings, and head coverings
  • Sanitary products, such as those for feminine hygiene and disposable diapers
  • Oil and liquid adsorbents, which are products that contain spills and pick up oil from the water
  • Coffee filters and tea bags
  • Artificial turf
  • Insulating products
  • Meat and vegetable packing trays
  • Disposable disinfectant wipes

 

What is melt blown process?

The melt blown process is a unique among nonwoven systems. Fundamentally it is a high tech version of the making of cotton candy at amusement parks. In making cotton candy, sugar is melted and pressure fed through small openings in a rotary spinning wheel. Upon exciting, the molten sugar congeals and is stretched into short fibres by centrifugal forces. In the melt blown system, molten polymers are forced through small slit openings and high temperature (230oC-390oC) air is impinged (300-500 miles/hr) at both sides of the exiting film. The fast-moving air streams effectively stretch or attenuate the molten polymer by multiple orders of magnitude and solidify it into a random array of discontinuous subdenier fibers. The fibers are then condensed (separated from the air stream) as a randomly entangled web and compressed between heated rolls. This paper deals with manufacturing technology, type of polymers used, web characteristics, properties and its various applications.

 

How to maintain of meltblown production line?

1. Routine maintenance. With cleaning, lubrication, inspection and fastening as the center, routine inspection and maintenance shall be carried out before, during and after each shift. Routine maintenance is done by the operator of non-woven production line independently.

2. Regular maintenance. According to the maintenance requirements, after reaching the specified working hours or the specified time, it is necessary to carry out the corresponding regular maintenance. The non-woven production line is a machine for processing non-woven fabrics to produce various products. The non-woven production line mainly includes: non-woven bag machine, non-woven slitting machine, non-woven surgical clothing machine, non-woven filter cotton weaving machine, non-woven shoe cover machine, non-woven glove machine, non-woven fruit cover machine, non-woven doctor's hat machine, non-woven nurse's hat machine, non-woven pillow core cover machine Non woven eye Mask Machine, non-woven punching machine, non-woven rewinder and other machines.

 

The maintenance of the non-woven production line is still very necessary, because if we do not pay attention to the maintenance, the use of various parts may not be so smooth, and the use of the whole non-woven production line will also be affected, which will directly lead to the decline of the production capacity of the factory.

 

What is meltbolwn Web Characteristics and Properties?

Uniformity

The uniformity of the web is controlled by two important parameters: uniform distribution of fiber in the air stream and proper adjustment of the vacuum level under the forming wire or belt. Non-uniform distribution of fiber in the air stream can result from poor die design and from non-uniform ambient airflow into the air stream. The vacuum under the forming media should be adjusted to pull the total air stream through the media and lock the fibers in place. Generally, the closer the die is to the forming drum or belt, the better the web uniformity.

 

Filtration media

This market segment continues to be the largest single application. The best known application is the surgical face mask filter media. The applications include both liquid filtration and gaseous filtration. Some of them are found in cartridge filters, clean room filters and others.

 

Medical fabrics

The second largest meltblown market is in medical/surgical applications. The major segments are disposable gown and drape market and sterilization wrap segment.

 

Sanitary products

Meltblown products are used in two types of sanitary protection products feminine sanitary napkin and disposable adult incontinence absorbent products.

 

Oil adsorbents

Melt blown materials in variety of physical forms are designed to pick up oily materials. The best known application is the use of sorbents to pick up oil from the surface of water, such as encountered in an accidental oil spill.

 

Apparel

The apparel applications of melt-blown products fall into three market segments: thermal insulation, disposable industrial apparel and substrate for synthetic leather. The thermal insulation applications takes advantage of microvoids in the structure filled with quiescent air, resulting in excellent thermal insulation.

 

Hot-melt adhesives

The melt-blown process has a special feature: it can handle almost any type of thermoplastic material. Thus, the task of formulating a hot-melt adhesive to provide specific properties can be greatly simplified by using the melt blown system to form the final uniform adhesive web.

 

Electronic specialties

Two major applications exist in the electronics specialties market for melt blown webs. One is as the liner fabric in computer floppy disks and the other as battery separators and as insulation in capacitors.

 

Miscellaneous applications

Interesting applications in this segment are manufacture of tents and elastomeric nonwoven fabrics which have the same appearance as continuous filament spunbonded products.

 

How to repair meltblown production line?

The production process of the melt-blown non-woven machineis a streamlined process, and any problem in any link may cause production interruption. So when the melt-blown nonwoven fabric machine fails, we must repair it in time.

 

 

Mechanical issues

When some mechanical failures occur, it is easier to find and solve them. For example, if a certain drive roller bearing is broken, it will make abnormal noises, and it is easy to find suitable accessories to replace. Or the reducer of the screw is broken, which will obviously cause speed fluctuations and make loud noises.

 

 

Electrical problems

But electrical problems, if there is a failure, are relatively hidden. For example, if a contact of the PLC is broken, it will cause abnormal linkage. A certain drive optocoupler of the frequency converter is abnormal, which causes the motor's three-phase current to fluctuate severely and even stops due to lack of phase. The parameters on the winding tension are not well-matched, which will cause the winding to be irregular. Or a certain line leaks, causing the entire production line to trip and fail to boot.

 

 

The touch screen does not work well

The touch glass of the touch screen needs to be dealt with in time because it is pressed too much, or dust and grease ran to the inner cable head, causing poor contact or aging of the touch panel, causing pressing failure or failure.

 

 

PLC failure

PLC is generally less broken, but it does not mean that it will not be broken. Generally speaking, the contacts and power supply are mostly burned. Relative to the problem, it is simple and quick to deal with. If the program is lost or the motherboard has a problem, the entire production line will be paralyzed. Find a professional company to help solve it.

 

 

Use power of inverter and tension control system

 

Because in this type of equipment, the power used by the inverter and the tension control system is relatively large. If the site does not pay attention to cold cutting and dust removal, it is easy to stop due to high temperature and static electricity during the production process.

 

Different failure points have different maintenance methods. We need to check the parts of the melt-blown nonwoven fabric making machine and the operation problems frequently.

 

What is meltbolwn Web Characteristics and Properties?

Uniformity

The uniformity of the web is controlled by two important parameters: uniform distribution of fiber in the air stream and proper adjustment of the vacuum level under the forming wire or belt. Non-uniform distribution of fiber in the air stream can result from poor die design and from non-uniform ambient airflow into the air stream. The vacuum under the forming media should be adjusted to pull the total air stream through the media and lock the fibers in place. Generally, the closer the die is to the forming drum or belt, the better the web uniformity.

 

Filtration media

This market segment continues to be the largest single application. The best known application is the surgical face mask filter media. The applications include both liquid filtration and gaseous filtration. Some of them are found in cartridge filters, clean room filters and others.

 

Medical fabrics

The second largest meltblown market is in medical/surgical applications. The major segments are disposable gown and drape market and sterilization wrap segment.

 

Sanitary products

Meltblown products are used in two types of sanitary protection products feminine sanitary napkin and disposable adult incontinence absorbent products.

 

Oil adsorbents

Melt blown materials in variety of physical forms are designed to pick up oily materials. The best known application is the use of sorbents to pick up oil from the surface of water, such as encountered in an accidental oil spill.

 

Apparel

The apparel applications of melt-blown products fall into three market segments: thermal insulation, disposable industrial apparel and substrate for synthetic leather. The thermal insulation applications takes advantage of microvoids in the structure filled with quiescent air, resulting in excellent thermal insulation.

 

Hot-melt adhesives

The melt-blown process has a special feature: it can handle almost any type of thermoplastic material. Thus, the task of formulating a hot-melt adhesive to provide specific properties can be greatly simplified by using the melt blown system to form the final uniform adhesive web.

 

Electronic specialties

Two major applications exist in the electronics specialties market for melt blown webs. One is as the liner fabric in computer floppy disks and the other as battery separators and as insulation in capacitors.

 

Miscellaneous applications

Interesting applications in this segment are manufacture of tents and elastomeric nonwoven fabrics which have the same appearance as continuous filament spunbonded products.

 

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