Meltblown Fabric Production Line
Machine Description of Meltblown Fabric Production Line:
Product
USE Range
Schematic Diagram of meltblown fabric making machine:
Characteristics of Meltblown Fabric Production Line:
Product model | DCWS-1600SMS | DCWS2400SMS | DCWS-3200SMS | DCWS-4200SMS |
Die number | SS:2+M:1 | |||
Filament number | 1.5-2.5d /2-55um | |||
Gram weight range | 10-100 g/sq.m | |||
Maximum operating speed | 500 m/min | |||
Effective wide | 1600mm | 2400mm | 3200mm | 4200mm |
The daily production capacity | 11000Kgs | 16000Kgs | 20000Kgs | 28000Kgs |
Technical Data of Meltblown Production Line:
NO. | Item | Index |
1 | Raw material | Polypropylene chips (Melt index: 20-40g/10min, with variation not more than 1% for each batch; Melt point: 165℃; Ash content: ≤ 0.15-0.25% |
2 | Width of finished fabric | 3200mm |
3 | Single filament titer | 1.5-2.5 denier |
4 | Daily output | 20MT/Day based on 40gsm |
5 | Web weight | 9-120 g/m2 |
6 | GSM Variation | CV (Coefficient Variation) value less than 6 % |
7 | Extruder size | φ170×30:1 |
8 | Process speed | 10~350m/min |
9 | Mechanical Speed | 10~400m/min |
10 | Power requirement | Loading 2200kva Actually 1760kva |
11 | Space requirement | 40*28*12m |
12 | No. Of S spin beams | 2set |
13 | No. of M spin beams | 1 set |
Main Equipment for Spunbond Section
No | Item/BRAND | Quantity |
1 | 1+3 Volumetric dosing hopper | 2set |
2 | Suction, dosing and mixing device | 2set |
3 | 170mm Main extruder | 2set |
4 | Co- extruder | 2set |
5 | Candle Style filter | 2set |
6 | 300cc Metering pump | 2set |
7 | Spinning machine | 2set |
8 | Spinneret plate | 4set |
9 | Filament quenching and drawing system | 2set |
10 | Web former | 1set |
11 | Embossed hot thermal bonding calendar | 1set |
12 | Winder | 1set |
13 | Slitter | 1set |
14 | Steel frame for main machine | 1set |
15 | Electrical control system ("SIEMENS" PLC control system) | 1set |
Auxiliary Equipment
SN | Item/BRAND | Quantity |
1 | Calcinator cleaner--YANCHENG | 1set |
2 | Ultrasonic cleaner--ZHANG JIA GANG | 1set |
3 | Assembly and disassembly device for spin pack | 1set |
Utility Equipment
SN | Item/BRAND | Quantity |
1 | Chiller-- HANBELL/SHUANGFENG(500000Kcal) | 1 set |
2 | Cooling tower-- HANBELL/SHUANGFENG(120Ton) | 1 set |
3 | Suction blower--FUZHOU (75KW) | 1 set |
4 | Suction blower--FUZHOU (110KW) | 1 set |
5 | Cooling blower--FUZHOU (90KW) | 2 set |
5 | Monomer blower--FUZHOU (11KW) | 2 set |
6 | Spinning Heating System--YAN CHENG (48KW) | 2 set |
7 | Calendar Heating System--YAN CHENG (72KW) | 2 set |
8 | Air Compressor--FUZHOU (11KW) | 1 set |
Main Equipment for Meltblown Section
NO. | Item | Qty | Specification |
1 | M Extruder | 1 | ф130, heating:90kw, motor 110kw |
2 | M hopper | 1 | Vacuum pump:11kw |
3 | M screenchanger | 1 | Filter mesh D:80mm. with filter200 pcs |
4 | M spin pump | 1 | 150CC，heating and running motor:4kw |
5 | M Die head | 1 | Solo entrance |
6 | M Spinneret | 2 | Hole size: 0.3mm,1"=40, Group assemble. filter mesh: 15pcs |
7 | M air heater | 1 | 500kw, tem0-300℃ |
8 | M suction blower | 1 | 160KW capacity: 60000m3/hr/ |
1 | Air pressure: 5800pa | ||
9 | M Roots blower | 1 | 160KW, capacity: 60m3/hr |
10 | Electrical panel | 1 | SIEMENS 14" touchscreen |
11 | Moving platform | 1 | |
12 | Die head up and down moving | NIL | Moving height:100mm-300mm. |
List of consumables
S.N. | Particular | Specification | Qty | |
1 | Air shaft | Ø74x 3700mm | 3nos. | |
2 | Convey belt | 31mx3.65m | 3nos. | |
3 | Pnumetic seal | 3600mm | 4nos. | |
4 | Teflone wire | 3.5mm dia | 50mtr | |
5 | Rectangular mesh | 3.2m x 3.435m | 20pcs | |
6 | Circle seal (for filter) | Ø202 x 5 (big), Ø60xØ50x4(small) | 50pcs | |
Filter(for candle filter) | Ø35x485 180mesh | 19pcs | ||
7 | Fuze | 2A,500V | 3set | |
8 | Fuze CHINT | input-3-32VAC | 5nos. | |
| solid state relay | Output-40-80A |
| |
| Schneider | load-480 VAC |
| |
9 |
| WZ-PT-100 | 3nos. | |
| temperature sensor | OD-170mm |
| |
| Yafei | ID-140mm |
| |
|
| Thk-16mm |
| |
10 |
| PT-124, 30Mpa, M22*1.5, 10V | 2nos. | |
| Pressure sensors (after-filter) | PT-492-20Mpa, 15/46, 0-20Mpa10vAC | 2nos. | |
11 | Pressure sensors | PW-806 | 1nos. | |
| Pressure indicator | REX-F-900 | 1nos. | |
12 | Xianda | CH-402 | 1nos. | |
| Temperature controller | CD-901 | 1nos. | |
13 | RKC | 0-16 Mpa | 1nos. | |
14 | Hydraullic pressure Guage | GSC1-0910 | 2nos. | |
| Contactors | GSC1-3210 | 1nos. | |
| Schneider | GSC1-5011 | 1nos. | |
15 |
| rotary model | 1nos. | |
| Photoelectric switch | OVWZ-15-2MHT |
| |
| CHINT | resolution-1500P/R-050-00 |
| |
16 | Fuze CHINT | E3F-DS-10Pi | E3F-DS-10Pi | 1nos each |
| solid state relay | U-12to24VAC | 6-36VAC |
|
| Schneider | I-200mA | 300mA |
|
|
| pnp-NU,Sn-10cm |
|
|
| Fuze CHINT | LJ12A3-4-Z/BY |
|
|
| solid state relay | 6-30VAC,200mA |
|
|
Description of Units
Dosing device
Charging device and function description
The chips are sent from the ground to the batching and mixing system on the third floor. then
The main materials and auxiliary materials can be prepared in a scientific proportion.
The batching and mixing devices are as follows: one main charging tank, two auxiliary tanks, one mixing tank and one suction device.
technical data
Additive I addition ratio: 0.5-5%
Additive II addition ratio: 0.5-5%
Additive III addition ratio: 5-50% (filling)
Maximum capacity of main materials: 500kg/h
170mm Main extruder --ZHOUSHAN
Technical Data
Screw size: Φ170
L/D ratio: 30/1
Max. Extruding capacity: 500kg/h
Rotary speed of screw: 20-80r/min
Power: 132 kw
Heating power: 110kw
No. of heating zones: 7
Edge recycle extruder--ZHOUSHAN
Technical Data
Screw size: φ105 x 15
Heating power: 12kW
Dragging power: 18.5kW
No. of heating zones: 4
Spinning machine--ALLWELL
Technical Data
Melt pre-filter --
Type: Candle style
Filter area: 3.5㎡
Candle type filter
Metering pump and its drive
Metering capacity: 300cc/r
No. of pump: 3 set
Motor power: 7.5kw
Monomer suction device
Motor power: 11kw
Size: 4070x610x1050mm
Spin pack
Material of spinneret and distribution plate: SUS431
Holes No. of spinneret: approx. 20400
Diameter of spinneret hole: Φ0.45mm
External dimension : 3510x216x30mm
L/D ratio: 4:1
Quenching and drawing system
Function
Used for the cooling and drawing of filaments, including quenching chamber, upper drawing channel, lower drawing channel, and diffusion channel. Double-side symmetric quenching is used, and the gap of the lower drawing chamber can be regulated as per the process requirements.
Technical Data
Made of section and δ=3mm mirror stainless plate
The inner clearance is adjustable
Max. working width: 3200mm
Quenching air volume: 10,000m3/h
Pressure: approx. 5000Pa
 |  |
| Up drawing system | Down drawing system |
Web former--ALLWELL
Function
Used to supply carrier for the drawn fiber webs, including a drive system for web forming belt, a suction channel device, a sealing device, an automatic correcting device, belt tensioning device, a frame and a prepressing roller, oil furnace and web support roll.
Technical Data
Process speed: 10-350m/min
Air permeating ratio of web forming belt: approx.8000- 10000m3/h.m2
Calendar--GUANGYU OR QIAODE
Function
Used for bonding formed webs by pressure and heating.
Technical Data
Process speed: 10-350m/min
Roller width: 3600mm
Roller type: engraved upper roll and plain lower roll
Drive method: individual motor and oil furnace for each roll
Winder--ALLWELL
Function
Used for winding the webs on rolls. Including two plain rolls and two pneumatic rolls.
Technical Data
Process speed: 10-350m/min
Working width: 3200mm
Max. winding diameter: 1500mm
A.C. frequency motor for main drive, automatic tension control system
Slitter
Function
Used for cutting wound rolls. Including four pneumatic rolls
Technical Data
Mechanical speed: 10-600m/min
Working width: 3200mm
Max. Diameter of finished fabric roller: Φ1200mm
Electric Power
Control | Power | Control unit | Brand | |
Feeding equipment | Main machine | 7.5KW | Auto | Lack of raw material alarm |
Main extruder | Main machine | AC110KW | Eurothern590C | Xi'an Sima |
Cooling blower | AC1.1KW | Motor protection + contactor | ||
Temperature controller | 7 area AC380V 18KW | Solid state relay control | RKC | |
Master batch extruder | AC 0.55KW | Frequency control | Siemens | |
Additive extruder | AC 0.55KW | Frequency control | Siemens | |
Co-extruder | Main machine | AC 18.5KW | Frequency control | Siemens |
Temperature controller | 4 area AC220V 3KW | Solid state relay control | RKC | |
Recycling suction system | AC 0.75KW | Frequency control | Siemens | |
Pressure meter | Pre-filter pressure | PW 808 | ||
After-filter pressure | F 900 | RKC | ||
Filter cabin pressure | PW 808 | |||
Melting temperature display | RKC | |||
Metering Pump | Main machine | AC 5.5KW | Frequency control | Siemens |
Cooling Blower | Siemens | AC 75KW | Frequency control | Siemens |
Stretch blower | Siemens | AC 55KW | Frequency control | Siemens |
Suction blower | Siemens | AC 7.5KW | Frequency control | Siemens |
Cooling system temperature display | RKC | |||
Web former | Main system | AC 18.5KW | Eurothern590C | Xi'an Sima |
Cooling blower | AC 0.09KW | Motor protection + contactor | ||
Calender | Main system | AC 44KW | Eurothern590C | Xi'an Sima |
Cooling blower | AC 0.37KW | Motor protection + contactor | ||
Grease oil pump | AC 1.1KW | Motor protection + contactor | ||
Lifting oil pump | AC 4KW | Motor protection + contactor | ||
Oil control | Oil temperature display | RKC | ||
Rewinder | AC 15KW | Frequency control | Siemens | |
Slitter | AC 11KW | Frequency control | Siemens | |
Touch screen | 10 inches | Siemens |
What is meltblown fabric?
Meltblown fabric is a non-woven fabric made of high MFI (1200/1500/1800g/10min, Condition 2.16kg, 230℃) PP as the main raw material and made by meltblown method.
Melt blowing is a spinning method that uses high-speed hot air to rapidly stretch, solidify and shape the polymer melt that has just been extruded. The advantage is that the process flow is short, and it can be directly spun to produce non-woven fabrics.
The fiber diameter of the meltblown cloth can reach 1 to 5 microns. These ultra-fine fibers with unique capillary structure have many pores, fluffy structure and good folding resistance, which increases the number and surface area of fibers per unit area, so that the meltblown cloth has good filtration, shielding, heat insulation and oil absorption.
The most important reason why meltblown fabrics are much better than ordinary non-woven fabrics is electret treatment. Through electret treatment, PP meltblown cloth is electrostatically charged, which can effectively adsorb and block viruses.
Meltblown fabric application
Medical and sanitary cloths: surgical gowns, protective clothing, sterilization wraps, masks, diapers, sanitary napkins, etc.
Home improvement fabrics: wall stickers, tablecloths, bed sheets, bedspreads, etc.
Clothing fabrics: linings, adhesive linings, flakes, shaped cotton, all kinds of synthetic leather base fabrics, etc.
Industrial cloth: filter material, HEPA filter, insulating material, cement bag, geotextile, covering cloth, etc.
Agricultural cloth: crop protection cloth, nursery cloth, irrigation cloth, thermal insulation curtain, etc.
Others: space cotton, thermal insulation materials, linoleum, cigarette filters, tea bags, etc.
Meltblown fabric is a key material used in countless applications across many industries. For example, in the production of masks, the fabric uses meltblown PP (polypropylene) as the main raw material to manufacture the key components of masks.
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