Spunmelt nonwoven production: Spunbond & Meltblown
The filter material in your face masks is made by, so called, spunmelt extrusion processes. In the Spunbond process polymer granules are melted and molten polymer is extruded through spinnerets. The continuous filaments are cooled and deposited on to a conveyor belt to form a uniform web. In Meltblown web formation, low viscosity polymers are extruded into a high velocity airstream on leaving the spinneret.
Contamination on the process belts
Both Spunbond and Meltblown are known to create contamination issues on the conveyor belt (also known as spinbelt), each process having its specific characteristics and belt contamination issues. Belt contamination reduces runnability of the production line and therefore output of face-mask material of the whole plant.
Problems caused by contamination
The local contamination, such as drips and “ropes”, cause uneven and non-uniform formation of the web in cross machine direction, leading to thinner areas in the web and even holes. The overall contamination, such as dust, short fibers, monomer and spin finish, cause a decreased permeability, leading to more drag of the belt on the vacuum boxes. This will wear the belts prematurely and therefor shorter lifetime. All in all, contamination on the belt leads to poor runnability of the line, web quality issues and premature wear of belts.
ProJet b.v., a company from the Netherlands, has invented a continuous spinbelt cleaning system, the Power Cleaner, which will continuously, 24h/day, clean off effectively all types of contamination. Using a brush to clean of “ropes”, high pressure heated water for monomer, short meltblown fibers, dust and spin finish, the Power Cleaner system will maintain optimum permeability of the belts throughout the life and significantly increasing lifetime of the belt. By doing so, runnability of the machine is optimized and quality of the web is secured.
ProJet successfully started up a Power Belt Cleaner at Berry Global, San Luis Potosi, Mexico. Later this year, 2 more Spinbelt Cleaners will be started up that were delivered earlier in 2022:
- Saudi German Nonwovens, Damman, Saudi Arabia
- Nanhai Nonwovens, Nanhai, China
ProJet understands that each client application is unique. For that reason, ProJet developed an automated ROI-calculator that will be applied to each application and produced paper grade. By contacting email@example.com or firstname.lastname@example.org ProJet will perform a no-charge ROI calculation of any Forming Fabric, Press Felt or Dryer Fabric application. After inputting the process parameters provided by customers, they will be provided with a ROI-Analysis of each specific application and investment justification