Melt-blowing has been an effective conventional method of creating synthetic fabrics on an industrial scale. The process is highly efficient at producing micro and nano with an average diameter as small as 36 nm. The melt-blow fabric production line involves melting a polymer extruded by high-speed blowing gas through tiny nozzles.
Meanwhile, Boyu and many other big names in the melt-blown fabric production line use this process to create various products. The nonwoven fabric sheet obtained due to the process is used in filtration, sorbets, hygiene, apparel, and drug delivery applications.
Along these lines, here two types of this process will be discussed: single blow melt-blown fabric line and double blow melt-blown fabric line.
The Differences Between Single Blow Melt-Blown Fabric Line and Double Blow Melt-Blown Fabric Line
As mentioned above, the melt-blown nonwoven process is categorized into two types throughout the melt-blown fabric production line. These are the single blow melt-blown fabric production line and the double blow melt-blown fabric production line. And some striking contrasts can be found in the two varieties.
- The single blow melt-blown fabric production line produces a fabric of melt-blown fabric. On the other hand, the double blow melt-blown fabric line can make double-layer melt-blown fabric.
- The double blow melt-blown fabric production line can be about two, or three times greater than the single blow melt-blown fabric production line in terms of capacity.
- Single blow melt-blown fabric production line provides a 90-95% filter ratio or efficiency, while the double goes up by 95-99 % efficiency.
The Process of Single Blow Melt-Blown Fabric Line and Double Blow Melt-Blown Fabric Line
Although they have differences in some areas, both single blow melt-blown fabric production lines and double blow melt-blown fabric production lines perform the same task.
The components used in both the single and double blow melt-blown fabric production lines are a suction fan, heater, calciner, blower, electret treatment machine, intelligent slitting and winding machine, and smart web forming machine. Furthermore, the process of any standard melt-blown nonwoven machine can be broken down into the following steps:
Polymer Mixing: Polymer mixing involves the process with the raw material of a thermoplastic resin polymer. Often Polypropylene, Polycarbonate, Polybutylene Terephthalate, Polyamide, Thermo-plastic Polyurethane, and Elastic Polypropylene are used. In this process, the polymers in pellets are stored and fed to an extruder hopper.
Melt Extrusion: The pellets are heated in the extruder to the melting point, where a screw impeller moves them through three zones. The feed zone is where the material entered for melting, followed by the transition zone where it is compressed. The last is the metering zone. The molten material is fed and prepared for the melt-blown die assembly through added pressure.
Filter: At the end of the metering zone, a screen pack acts as a filter to prevent any debris, dirt, or lumps from reaching the metering melt pump. At this point, the molten polymer has reached around 250 °C – 300 °C.
Melt Pump: This is a positive displacement pump specifically designed to deliver a constant volume of pure molten polymer to the die assembly.
Melt-Blown Die Assembly: The die assembly is where the melt-blown unwoven fabric is formed. It consists of three components; the feed distribution, the die nosepiece, and the air manifolds. The die nosepiece is critical as it determines the uniformity of the output of the melt-blown nonwoven process.
Hot Air Stream or Electret Treatment: These processes are used to help solidify the resulting microfibers from the air manifolds of the die assembly. The microfibers are directed towards a collector screen where they bind together to form cohesion and entanglement of fibers.
Winding System: After the fabric has cooled down, it is taken from the collector screen and wound onto a cardboard core of the winder unit.
The Applications of Single Blow Melt-Blown Fabric Line and Double Blow Melt-Blown Fabric Line
Both the single and double blow melt-blown nonwoven processes yield a fabric that has many applications. These applications may range from medical masks, tissue paper to bedsheets, table cloths, bed covers, and other household fabrics. It is also used to manufacture filter materials (air-conditioning filters and collecting oil contamination) and other products in the industrial, agriculture, and R&D industry. Likewise, it finds its applications in hygiene products such as disposable diapers.
Although the single blow melt-blown fabric production line and the double blow melt-blown fabric production line have something different, the performance is the same. The applications of these two processes can be found in people’s daily life.
For example, due to the coronavirus outbreak, the demands for face masks are on an unprecedented scale. As the primary material of face masks, the melt-blown fabric is essential. Such an atmosphere attracts manufacturers investing in melt-blown fabric production lines. So, if you want to find a capable provider with this process, here is one for your reference.
Boyu, a proficient melt-blown fabric production line provider, offers you state-of-the-art products and melt-blown nonwoven fabric production solutions. Its capable products are welcomed by people worldwide. It centers around the improvement pattern of the top of the melt-blown nonwoven market and unites the advanced technology/equipment of the global nonwoven industry with its research and development capability. Moreover, Boyu is CE certified for single screw and twin-screw extruders. It will provide you with the most satisfactory consultation to finalize your choice.