POOR, Se TECHNICAL GUIDE TO PP Nonwoven Process eo HPCL-Mittal Energy Limited Customer Services & Development Center ‘4-27, Sector 65, Noida ~ 201301 U.P. INDIA Phone: 0120-4634972Piece) ss a NST Berar 3-6 Neuse tear euler es eg Resin Selection for Nonwoven Process 7 Effect of Resin Variables on Nonwoven Process 8 Dae OR la ecu cacte 8-9 Paterna CE eal 9-10 Bea aCe tur Cr Cy Foran CNN agrees an Contents\ INTRODUCTION ‘onwoven fabrics are broadly defined as web structures bonded together by mechanically entangling the fibres, thermally fusing the fibres or chemically bonding the fibres. Nonwoven Process, in general, rely on high volume production which is highly engineered and, because of competitive market, there isa constant need to innovate for offering high quality products at the minimum cost. The right quality polymer selection for nonwoven process, plays a vital role on the finished goods performance, mainly significant improvements in technologies. The major three Nonwoven process are ~ (1) Spun bond or Spunlaid Nonwoven Process, (2) Melt Blown Nonwoven Process & (3) Staple Nonwoven Process Ts Nonwoven fabricis manufactured by different Each technology has their own unique advantage over 1, Spunbond Technology ‘nthe spun bond technology, usually a thermoplastic fibre forming polymer is extruded to form fine filament fibres of around 15-35 micrometre diameter. The filaments are attenuated and collected ‘on conveyor belt in the form of a web. The filaments in web are then bonded to make spunbond nonwoven fabric. ‘The Spunbond Process is a continuous process, consists ‘of multiple integrated steps - Polymer Feeding, Melting, Filtration, Melt Pumping, Spinning, Quenching, Drawing, Web formation, Bonding & Winding. Feeding of Polymer: The PP Granules along with the required ingredients (e.g, Colour Masterbatches, Filler, etc.) based on the end use requirement, are fedin tothe extruder hopper, which is placed at the top of the plant. Inthis process another small satellite or Jockey extruder are being used to feed unused fabric or colour master batches, ifany. Melting: The pellets are then supplied to an extruder screw, which rotates within the heated barrel. As the pellets are conveyed forward along the hot walls of the barrel between the flights of the screw, the polymer moves along the barrel. The solid polymer melts due to the heat and friction of the viscous flow and the 1B Wi Ld ae eC cele Mateo ag fabric's physical and mechanical properties including fabric handling and drawability, tensile properties, abrasion resistance and printing that create prospects fornonwoven fabric applications. This technical guide briefly discusses on the various nonwoven fabric production processes including web formation, web consolidation and finishing. An introduction to various adhesion techniques is also discussed along with resin selection and HMEL Polysure grade offering andat the end, a troubleshooting guide. the other & different polymers are recommended to use in different technology. The two important polymer-extrusion based technologies that are mainly used to convert the molten Polypropylene (PP) into nonwoven fabrics are Spunbond technology and Meltblown technology. mechanical action between the screw and barrel. The melted polymer is discharged to the metering zone, Which serves to generate maximum pressure for pumping the molten polymer. Filtration: The molten polymer passes through the breaker plate with a screen pack, placed near the screw discharge. The screen pack and breaker plate also filter out dirt and unmelted polymer lumps. The pressurized molten polymer is then conveyed to the met. pump. Melt Pumping: A positive displacement volume ‘metering device is used for uniform melt delivery to the die assembly. The metering pump typically has two intermeshing, counter-rotating, toothed gears. The positive displacement is accomplished by filling each gear tooth with polymer on the suction side of the pump and carrying the polymer around to the pump discharge. The molten polymer from the gear pump goes to the feed distribution system to provide uniform flow to the die nosepiece in the die assembly. It ensures the consistent flow of clean polymer mix under process variations in viscosity, pressure and temperature. The ‘metering pump also provides polymer metering andthe required processpressure. Guide to PP Nonwoven Process -Polymer extrude Forming, dg Guid Guide Spinning: The spinning operation is most important part in the Spunbond process, which is done by heated die assembly. The uniform temperature (220°C -280°C) across the die is maintained by circulating hot oil or Electric Heater. This assembly is divided in two sections - Polymer feed distribution section and Spinneret, The feed distribution balances both the flow and the residence time across the width of the die. There are basically two types of feed distribution - T-type (tapered and untapered) and Coat-hanger type. The T-type feed distribution is widely used because it gives both even polymer flow and even residence time across the full width of the die. A spinneret is made from a single block of metal having several thousand drilled orifices. The orifices or holes are followed a certain pattern. The spinnerets are usually circular or rectangular in shape. The grouping of spinnerets is often called a block or bank. In wide width production line, multiple blocks are used in order to increase the coverage of the filaments. From the feed distribution channel the polymer melt goes directly to the spinneret from where narrow polymer fibre are produced. ‘Quenching: The emitted filament passes through the quenching chamber, where the cooling is done by low temperature (8-15 °C) air circulation from single or both. side of the chamber. The double side cooling helps in faster solidification of the filament, Filte Pum: Spin Quench Attenuatio Compaction Fig. 1~Schemati Diagram of Spunbond Nonwoven Process Fie. 2~ Spinner Fibre Spinning ical Guide to PP Nonwoven ProcessDrawing: Filament drawing follows spinning. In most of ‘the process, the filaments are drawn by gravitational force in presence of suction pressure of the belt. In few spunbond process, 2 specially designed aerodynamic device such as a Venturi tube is commonly adopted for filament drawing. Web Formation: Filament deposition follows the drawing step. Filament deposition is also frequently achieved with the aid of a specially designed aerodynamic device referred to as a fanning or entangler unit. The fanning unit is intended to cross or translate adjacent filaments to increase cross- directional web. High pressure air is used to deposit the filaments on the belt & the vacuum below the belt helps toform the filamentweb. 2. Melt Blown Technology elt blowing is a conventional fabrication method of micro and nanofibers where a polymer melt is extruded through small nozzles surrounded by high speed blowing gas (mainly Air). The basic difference is the MFI of PP resin, used for Melt blown technology is quite high (Typical MF! 100 1600 g/10 min) as high polymer flow is essential. ‘The initial steps of Melt Blown technology - Polymer feeding, melting, filtration and melt pumping are similar in nature with Spunbond technology. The key to the melt blowing process is the spin head. The basic principle is the extrusion of low viscosity polymer melt through a single row of very fine holes placed close together in the order of 1000-4000 holes per meter. The major technology difference for melt blown process in the spinning stage, where hot air (Air temp 230- 360°C & Velocity = 172-275 m/s) is used to blow the polymer melt for generating the micro or nanofibers. ‘The fibers produced by this method are generally very weak with low tenacity and modulus because low molecular weight polymer is used. The other factor is ‘that hot air keeps the polymer in the melt state as it is being attenuated, which is necessary because of the rapid acceleration of the polymer as it exits the spin 3. Staple Nonwoven Process his a very old & conventional Nonwoven manufacturing process. There are four major steps involved in this process. Initially the fibre spinning is done followed by cutting of fibre in small pieces. Then the small fibre put into bales for proper Bonding: The loosely bonded fibres are entangled by several way of bonding — Mechanical Entanglement (Needle Punch & Hydro entanglement), Curing (Thermal Bonding) & Chemical Bonding (Chemical Reaction). Generally, the thermal bonding is most widely used, where the filament web is passed through a pair of hot metal embossed roll. The required roll temperature & Pressure help to fuse the filament and to form the Nonwoven fabric. Other bonding technologies are used for specific applications. Winding: After the bonding, the fabric is trimmed from both sides & the fabric is rolled on the winder. The nonwoven lines are classified based on the width of final fabric 1.6 meterlline, 3.2 meter line, Polymer tank Polymer melt Hot aie oy Hot air £%. Cooling air coolant Mel blown fibers i Collector Fig. 3~Melt Blown Process hole. This results in low axial molecular orientation in the fiberasitis being formed. After Microfiber formation, a flutter is developed in the air stream that causes the fibers to flap rapidly back and forth as they are cooled by ambient air becoming entrained in the process. Finally, the fibers are collected on a hollow Rolling Drum, where the web formation is done. The entrapped air is taking out from the web by maintaining the suction inside the drum. blending. After that all fibres are dispersed on a conveyor belt and spread in a uniform web by different technique ~ (1) Wetlaid, (2) Airlaid, (3) Carding / Crosslapping. Guide to PP Nonwoven Process -In Wetlaid process, the process is followed for fibre, having length from 0.64 to 1.91 cm, but sometimes longer if the fiber is stiff or thick. Airlaid processing generally uses 1.3 to 10.2 em longer fibers. Carding operations typically use~3.8cm long fibers. Staple nonwovens are bonded either thermally or by using resin. Very high flow polymer used as bonding resin. Bonding can be throughout the web by resin saturation or overall thermal bonding or in a distinct pattern via resin printing or thermal spot bonding Conforming with staple fibers usually refers to 2 ‘combination with melt blowing, often used in high-end textile insulations. Composites Line of Various Nonwoven Technology advantages & disadvantages. Spunbond process offer higher mechanical strength of the fabric, but the fibers are relatively higher in diameter, On the other hand, Meltblown process offers finest fabric which has performed very well for filtration & hygiene application, but not capable to offer mechanical strength. To overcome the shortcoming of each technology, new concept has developed by compositing both the technology inasingle process. E= processing technology has its unique Based on the specific requirement & applications, Melt Blown & Spunbond technology is clubbed in multiple Nonwoven Plant Cpacity & Fabric Weight onwoven Fabric is characterised by weight in grams of each square meter of fabric, ie. GSM Generally, thickness measurement is not done as the surface is embossed & the product is floppy types. The Plant capacity or output is calculated from the GSM of fabric, tape line width & Line speed of the Nonwoven Plant. The typical example has shown below. Line Speed = 22 MPM; Fabric GSM = 120 g; Fabric Width = 3.2 m layers ina single processing units. Below are the typical ‘examples of few composite systems. = SMS Line (Spunbond—Melt Blown-Spunbond) = SMMSS Line (Spunbond—Melt Blown-Melt Blown = Spunbond) = SMMMS Line (Spunbond ~ Melt Blown ~ Melt Blown—Melt Blown-Spunbond) = SSMMMS Line (Spunbond - Spunbond ~ Melt Blown—Melt Blown -Melt Blown—Spunbond) = SSMMMSS Line (Spunbond ~ Spunbond - Melt Blown ~ Melt Blown ~ Melt Blown ~ Spunbond - Spunbond) Plant Output = Line Speed X GSM X Width X 0.06 Kg/Hour (22 X 120 X 3.2 X 0.06) Kg/Hour = 507 Ke/Hour wy Yo cole Mallet Nei LL eo a present, Nonwoven fabrics are among the most versatile materials in the market. Unlike other fabrics and substrates that are made by knitting, weaving or other processes, advanced Nonwoven technologies ensure that fabrics are engineered to meet the strict performance demands of diverse applications. Nonwoven fabrics are a dynami value-added alternative to more traditional materials. The key benefits of Nonwoven Process & fabrics are below. Process Attributes Very compact and continuous process ~ Less man power requirement Q) Process capable to produce uniform wide width fabric with thin fibre &) Greater strength per basis weight than competing fabrics ‘Technical Gude to PP Nonwoven ProcessVery high Consistency in high temperature applications y to form composites for advanced performance Application specific modification possible dea Se Good Abrasion Resistance & High tear strength © Excellent Moisture & Chemical resistant to ‘many oils and solvents {rious resins are being used for the Nonwoven Process like Rayon, Polyester & Polypropylene. PP is the most widely used resin for Nonwoven process, Nonwoven process demands very specific requirements from resin to meet during filament and ‘fibre spinning process. Molecular weight and molecular weight distribution play a vital role in determining melt spinning characteristics and mechanical properties of resultant fibres, All polypropylene grades possess a range of polypropylene chains of differing length (or molecular ‘weight) even though they are commonly described by the average molecular weight. The resin with Narrow Molecular weight distribution is preferred for Nonwoven Process. Generally, PP resins are manufactured by Controlled Rheology peroxide crackingto achieve the following properties like - © Light weight & relatively high Temperature resistance ®) It doesn't deteriorate in the presence of bacteria, Fungus or other elements. It has good Insulation Properties & Low Thermal Conductivity Very soft, Moderate Strength & flexible — Easier to use in various applications wi Resin Selection for Nonwoven Process = Good processing stability = LowlevelofVolatile content = Efficient Stabilisation Package = Narrow molecular weight distribution resin * Good meltstrength to eliminate melt flow breaks = Cleanliness of polymer toavoid filter pack blockage * Material should have the good Spinability & drawability = Medium (25 ~ 40 MFl for Spunbond) to high melt flow (100-1600 MF! for Melt Blown) Additionally, resin should show superior thermal stability, gas fading stability during high temperature processing and inherent UV stability for outdoor application. Technical Gude to PP Nonwoven Process -wy Effect of Resin Variables on Nonwoven Process am Resin Properties Ce Molecular Weight is directly responsible for strength of polymer. aa Molecular Weight MFI Tenacity 12 Molecular Weight J MFI Tenacity | Molecular weight distribution is a function of catalyst system and polymerisation process. PP 2 with broad MWD is easier to process due to more shear sensitivity than the one with narrow Mw. 2a MWD (Broad) FRR ‘Not preferred for Nonwoven process 22 Mwp (Narrow) FRR Fibre Spinning 4 Draw down 3 Stereo regularity measured by Isotacticity aa Isotacticity Xylene solubility | Fabric hard feel Drawability 32 Isotacticity | Xylene solubility Fabric hard feel 1 Drawability ‘able 1 Coreation between Resin and Product Property wy Polysure PP Grade Offerings for Nonwoven Sector olysure PP Y35GR / Y3SGR1 are Controlled making fine denier monofilament yarns & non-woven Rheology Polypropylene homopolymers, fabrics. Grades exhibit inherent good processability produced by latest Novolen Technology / with high Melt Flow and Narrow MWD. Both the grades LyondellBasell Spheripol II Technology respectively & show superior resistance to gas fading and inherent are primarily suitable for fibre spinning operation for basic UVprotection, Polysure "Y35GR 35.0 Spunbond Nonwoven Fabric, Face Masks Excellent Spinnability & Anti PP "Y35GR1 35.0 & Medical Apron, Suit Covers, Diapers Gas Fading Property ‘rtin g/10 08 per ASTM 01238. Table 2~ Charactrietes of Poiyure PP Nonwoven Grade Melt Flow Index (230°C & 2.16 kg) ASTM 01238 g/10min. 35 2 Tensile Strength at Yield, Type ISpecimen acrurngyg MPa 33 32 3 Tensile Elongation at Yield, Type specimen (O™™/ min) gg u 10 4 Flexural Modulus (1% Secant) ASTM 07904 MPa 11501250 5 Notch Izod impact Strength (23°C) ASTM D256A —_J/m 30 30 6 —_Vicat Softening Point (20N) ASTM 01525 °C 153151 7 Heat Deflection Temperature (0.455 MPa) ASTM D648. °C 90 90 “A the mechanical properties are tested on injection mole Tet Seecimen prepared in accordance with ASTM D 4103, ‘able 3~ Properties of Polysure PP Nonwoven Grade ‘Technical Gude to PP Nonwoven ProcessY35GR / Y35GR1 Grade Benefits Includes eB S Excellent processability with narrow Molecular Weight Distribution Good Drawdown Properties ? “ty Consistency in Flow of material Excellent Spinability Go eee = Barrel Temperature: 195 - 235°C = Avg. Die Heater Temperature: 235 - 240°C = Quench Air Temperature: 15 - 18°C Boo Bags should be stored in dry & dust free environment at temperature below 50°C .Prevent from direct exposure to sunlight & heat to avoid quality deterioration. Rotini cen Polysure Polypropylene grades are manufactured complying the requirements specified in IS 10810 on “Specification for Polypropylene & its Copolymers for safe use in contact with Foodstuff, Pharmaceutical & Drinking water”. Furthermore, the Additives added in thi grade formulation compiles to the "Positive ‘onwoven fabrics are engineered fabrics that |\ esse atmos oy durable. Nonwoven fabrics suited for specific jobs, while achieving a good balance between product usedife and cost. They can mimic the appearance, texture and strength of a woven fabric and can be as list of constituents for Polypropylene, Polyethylene and their Copolymers for its safe use in contact with Foodstuffs & Pharmaceuticals’ as laid down under IS 16738:2018. In general, the additives & constituents used in the grade are in line with requirement laid down under FDA: CFR Title 21,177.1520, Olefin Polymers. Wi Application of Nonwoven Fabrics bulky as the thickest paddings. In combination with other materials they provide a spectrum of products with diverse properties, and are used alone or as ‘components of apparel, home furnishings, health care, engineering, industrial and consumer goods. Technical Guide to PP Nonwoven ProcessMedical = Surgical Mask = Medical Apron = Head Cover Flexible Packaging = Rice Packaging = Seed Packaging = Cattle Feed Packaging Shopping Bag ™ General Purpose Bag = Grocery Bag = Carry Bag Automotive = Seat Cover = Outdoor Car Cover "= Wheel Cover = Liner inside the Car Geotextile = Road Construction = River bank Protection Agriculture "Covering the Fruits © Shading of Plant = Plantation Industrial & Others = Cloths Liner = Shoe Cover = Carpet Backing BIG] Technicat Guide to PP NonWi Troubleshooting Guide for Nonwoven Process N ‘onwoven Process is a complex process involving multiple steps Many a times, we face processing & performance related difficulties during manufacturing of Nonwoven Fabrics. Although CTE Leo ee vy Beate CoN) FILAMENT. BREAKAGE DUE TO DEGRADATION FILAMENT BREAKAGE AT ‘SPINNERET Low ELONGATION OF FILAMENT FILAMENT BREAKAGE AT QUENCHING ZONE MELT DROPPING ON FABRIC FABRIC HARNESS, ROUGH ‘SURFACE OF FABRIC GsM VARIATION SHOTS ROPING FLY Moisture in material Pigment degradation High extrusion temperature Higher residence time Blockage of Spinneret holes Melt viscosity is too high/low Uneven melt flow Higher melt drawdown ratio Higher quench air temp Higher isotacticity of Polymer Melt draw down high Quench air velocity is high Worn out thread guides = Lower flow of material = Flow inconsistency in resin Blockage of Spinneret, Higher Bonding Roll Temp. Higher Processing Temp. Filament breakage Patch on Conveyer belt = Lower pressure in Bonding roll Inconsistency in Flow Fluctuation in Melt Pressure Excessively high temperature = Very High MFR, low MW. Uncontrolled air turbulence Violent blowing condition Table 4— Troubleshooting solutions for Nonwoven Process Disclaimer: The information & data presented herein re typical values & should not be considered as specification and may be used as guideline only. HMEL does not undertake any responsibilty for any outcome or results from the adoption or replication of the above mentioned data & information there on for possible use for various applications. HMEL reserves the right to change the Information & data without any prior notice or information. The user wil solely be responsible for any process/product usage. these issues vary from machine to machine, we have recommended the probable cause and remedy for few genericissue of the Nonwoven process. Use of hopper dryer Use of temperature resistant pigment Reduce melt temp Reduce residence time Die / Spinneret Cleaning to be done Replace damaged filter pack Optimizing extrusion temperature Check metering pump functioning Reduce take up velocity Adjust the Quench air temperature Use Polymer with higher XS Reduce take up velocity Reduce quench air velocity & Temp. Check thread guides Use High flow of material Use resin with narrow MFI Cleaning of Blockage Reduced the Roll temp. Adjust the processing temp. Ensure to stop filament breakage Clean the conveyer belt Reduce the gap of Press roll "Check the RPM of Metering Pump "Change the screen pack / filter = Adjust melt processing temperature Select resin of suitable MFR. Control the air stream speed & pressure Reduce the blowing air speed & pressure Technical Gude to PP Nonwoven ProcessCustomer Services & Development Center MEL has chartered on a goal to emerge as a responsible player in the Petrochemical Industry. HMEL has set upa state-of the-art Customer Services & Development Center (CSDC) at Noida to strengthen its customer vvalue proposition through Research & Development. HMEU's CSDCis equipped with sophisticated and advanced testing equipment andis aptly designed to have flexibility which allows diverse modes of testing. We are committed to produce consistent quality products in line with industry needs & always stand by our customers for all-round support for product, application and market development initiatives. Accreditation of CSDC = This center is accredited to ISO/IEC 17025:2017 by National Accreditation Board for Testing and Calibration Laboratories (NABL}, Govt. of India. = Further, Customer Services & Development Center (CSDC), Noida has been recognized and registered as one of the key scientific and industrial R&D facility by Department of Scientific & Industrial Research (DSIR), Ministry of Science and Technology, Govt. of india, ee HMEL HPCL-Mittal Energy Limited INOX Tower, Plot No. 17, Sector-16A, Noida ~ 201301 (U.P), India. Tel: 0120-4634500 @wwwhmel.in