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0809993 Neumag | Saurer
Spunbond Lines. Part of the unique Neumag Nonwoven Technology Portfolio.
Neumag | Saurer is the industry's first supplier for all major nonwoven processes. By bringing together the brands of Neumag, M&J, FOR, Autefa, Fehrer and Kortec, we created a unique portfolio of key technologies. This enables us to provide turnkey airlaid, carding, and spunbond lines as well as innovative technological concepts for nonwoven products - all from one source. Our customers benefit from the dynamic flexibility and specialist know-how of our key technology sites in Germany, Austria, Denmark and Italy.
Airlaid Airlay 1 Carding
Neumag Denmark Neumag Austria
Neumag Italy
Crosslapping
Neumag - Autefa
Spunbond
Spinning
Neumag
Meltblown
Chemical/Thermal
Winding
Needle punching
Neumag Austria
Festooning
Neumag
Spunlace
Slitting/Rewinding
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Neumag Spunbond Technology -the Flexible Way of Nonwovens Production
The main characteristic of Neumag's Spunbond Technology is the outstanding flexibility that the nonwovens producer has in supplying a wide variety of products and truly unique fabrics.
The Neumag Spunbond Technology allows the modification of the key process parameters of polymer spinning in a wide range for various fiber and web properties: • Choice of polymer (PR PET, PLA ...) • Wide range of polymer viscosity
(MFR 20 to 350) • Fiber size from micro-denier (< 0.7 dtex)
to coarse denier (> 4 dtex)
A wide range of diversified added value products as well as high quality commodity products can be produced cost-efficiently
The long term competitiveness of Neumag spunbond lines is guaranteed by the modular machine design allowing future upgrades at reasonable costs and with minimized downtime.
By combining the Neumag Spunbond Technology with other technologies from the Neumag Nonwoven Portfolio, like meltblown, carding, airlaid, needle punching or spunlacing, unique customer specific turnkey lines can be set up.
Neumag offers total solutions starting from full scope supply including complete engineering services, start-up and production support, up to guarantees for quality and capacity.
Neumag's close relationship with first-class downstream equipment suppliers provides an innovation network available to our customers for developing customized solutions.
The new fullsize Spunbond Solution Center (SSC) launched in January 2004 provides a full scale Neumag spunbond line for supporting our customers' product development.
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Applications and Products.
Just meltblown lines (without spunbond) for: • Air filtration (clean room, cabin air...) • Liquid filtration (water, beverage...) • Medical fabrics (face masks...)
Spunbond-meltblown lines (SMS or SMMS) for: • Barrier fabrics (protective clothing etc.) • Medical gowns, sterile wraps • Hygiene products
Spunbond lines (multiple beam) for: • Hygiene products • Agriculture • Bedding and furniture • Packaging • Industrial applications
Main Components of a Spunbond Plant,
Spunbond plant
1 Silo 2 Crystallizer (optional for PET, PLA) 3 Dryer (optional for PET, PLA) 4 Additive/Polymer metering 5 Extruder 6 Polymer distribution pipeline 7 Spinning beam 8 Spin pack 9 Quench (not shown)
10 11 12 13 14 15 16 17 18
Air handling unit Chilled water unit Draw slot Web former Calender Winder Rewinder Spinneret workshop Compressor room
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Features of the Spunbond Technology.
Spunbond spinning section
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Flexibility of Polymers and Viscosities Without any modification, a wide variety of melt spinnable polymers such as PP, PE, PET, PLA and PA can be processed on the same machine as mono or bico fiber with short switching times. Both high and low MFR or IV resins, ranging from MFR 20 to 350, can be spun most efficiently without any equipment alterations.
Segmented Dowtherm Vapor Heated Polymer Distribution For optimal spinning, the melt in the spinning beam has to be distributed to the spin pack under absolute uniform conditions. The uniform temperature profile is the key for excellent spinning stability which is provided by a Dowtherm vapor heated segmented polymer distribution system. It allows the processing of a wide range of different polymers and a large range of throughputs. Changes in chemical composition by thermal degradation of shear induced demixing are practically eliminated and it is not necessary to adjust temperature profiles for different polymers to achieve a uniform distribution of the polymer over the full width of the spinning beam.
Sheath-core bicomponent
Independent Process Settings The process steps of spinning/quenching, drawing and web-forming are decoupled and can be independently adjusted in a certain range. Encapsulation of quenching and forming zone guarantees stable process conditions.
Variable Spinning Length The distance between the spinneret and the draw slot (spinning length) is adjustable in a wide range. In order to achieve high filament speeds required for processing polymers like PET or for spinning low denier fibers, the spinning length can be minimized to reduce the drag force between fibers and air.
Variable Forming Distance The distance between the slot and forming wire is adjustable for achieving a perfect web formation for a particular product.
Variable Spinning Speeds By adjusting the spinning length and the pressure in the draw slot, a wide range of spinning speeds can be set. With the Neumag Spunbond Technology, it is possible to run polymers like PET and PLA which require high spinning speeds as well as thermoplastic elastomers requiring low spinning speeds, without changing the equipment, only by adjusting the appropriate process parameters.
Spinning pump drive
Dowtherm vapour
Dowtherm liquid
Dowtherm drain valve
Polymer inlet
Spinning beam insulation
Polymer distribution pipes
Spinning beam
Electrical heating elements
Electrical heating elements
Spinning pack
Features of the Meltblown Technology.
Bicomponent Capability The Neumag spunbond lines can be equipped with Neumag bicomponent technology proven on various commercial Neumag staple fiber and spunbond plants.
Two extruders are used to melt the different polymers which are fed to the spinning pumps integrated in the spinning beam. The two polymers are distributed via a segmented distribution system minimizing shear stress and are combined to a bicomponent fiber in the spin pack. The very robust design of polymer distribution and bico spinneret minimizes the risk of damage during cleaning.
Sheath-core is the most common fiber type in the nonwoven industry. The unique Neumag bicomponent system allows a sheath content as low as 5% creating considerable advantages: • excellent bonding of fibers with PE surface • good bonding against PP meltblown in
SMS fabrics providing superior softness • recycling of waste into core polymer stream
possible due to the very low amount of sheath polymer in the waste
Meltblown technology is used to produce nonwoven webs with ultra fine filaments. Neumag offers solutions for both the production of meltblown webs as well as composite lines including meltblown like SMS.
Neumag uses the well proven meltblown technology from its strategic partner KASEN. This technology is in operation in several commercial production lines worldwide. Meltblown products out of various polymers like PP, PET or thermoplastic elastomers can be produced with the KASEN Meltblown Technology.
The meltblown technology die is offered with a standard hole density of 35 holes per inch (hpi).
Die tips with 50 hpi are available for achieving higher barrier properties without decreasing the throughput.
Process Description.
Figures 1, 2 and 3 show the spunbond process in three different modes corresponding to different requirements of products to be produced, such as filament size, polymer type and fabric structure. The following features can be seen:
Figure 1: This setting is used to achieve an extremely high filament velocity of up to 5000 m/min for PP and 6000 m/min for PET which leads to a high orientation of the molecules in the fiber. This permits the production of PET fabrics with low thermal shrinkage without the need for post-treatment.
Figure 2: Machine settings with increased spinning length for achieving an optimized cooling of filaments for specific products.
Figure 3: Typical process setting for production of sub-denier PP fibers. Using spinnerets with a high hole density compensates the decrease of specific throughput per hole typical for sub-denier fibers.
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Line Configurations, (examples)
a) SMS Calender Winder PP, PET (optional bico)
Spunbond / Meltblown / Spunbond Calender Winder
b) Spunbond Spunlace Winder PP, PET (optional bico)
Spunbond / Spunbond Spunlace Dryer Winder
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Spunbond / Spunbond Needling Needling Winder
c) Spunbond Needling Winder PP, PET (optional bico)
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Spunbond / Airlaid / Spunbond Spunlace Dryer Winder
d) S/Airlaid/S Spunlace Winder PP, PET (optional bico)
The Neumag Spunbond Technology can be combined with the other Neumag nonwoven technologies in order to provide customized solutions for specific applications.
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Technical Data
PP Machine width
Beams
Line speed
Spinning speed
Production
(m]
[#] [m/min]
[m/min]
[kg/m/h]
up to 5.4
up to 3
up to 800 (mech.)
up to 5,000
up to 240
Standard
Spunbond beams (Meltblown beams can be added)
Varies ace. to polymer and filament size
Filament size
Lower end
Upper end
[dtex]
[dtex]
0.7
4.0 Other filament sizes available
PET Machine width
Beams
Line speed
Spinning speed
Production
[m]
[#] [m/min]
[m/min]
[kg/m/h]
up to 5.4
up to 3
up to 800 (mech.)
up to 6,000
up to 300
Standard
Spunbond beams (Meltblown beams can be added)
Varies ace. to polymer and filament size
Filament size
Lower end
Upper end
[dtex]
[dtex]
0.7
4.0 Other filament sizes available
BICO Machine width
Beams
Line speed
Spinning speed
Production
[m]
[#] [m/min]
[m/min]
[kg/m/h]
up to 5.4
up to 3
up to 800 (mech.)
up to 6,000
up to 240 (PP)
Standard
Spunbond beams (Meltblown beams can be added)
Varies ace. to polymer and filament size
up to 300 (PET)
Filament size
Lower end
Upper end
[dtex]
[dtex]
0.7
4.0 Other filament sizes available
Polymer PP, Co-PP, PET, Co-PET,
Vistamaxx (EXXON), Versify
(Dow) Eastman Eastar, PTT,
PE, PUE, PLA, TPU
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The Spunbond Solution Center.
Neumag as a leading manufacturer in the textile machinery business for BCF, staple fiber and non-wovens, pursues its own developments in these business areas. An extensive laboratory has been set up in Neumunster, Germany, with the latest generation of spunbond and meltblown technologies. In order to evaluate the potential of combined lines, similar development centers with pilot equipment are available at Neumag Denmark (airlaid) and Neumag Austria (carding).
Here we carry out improvements and developments of new processes, components and machines as well as trials for and together with our customers.
The high flexibility of the pilot line derived from the interchangeability and adaptability of the main components and configurations, allows the production of virtually every conceivable fabrics on a semi-commercial scale. Nearly all polymers are processable on the plant including full bicom-ponent capability. Due to the fact that the pilot plant is fully equipped and a "downsized" version of a production plant, the fabric properties of the trials are identically transferrable to larger production plants.
1 3
Engineering
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Our engineering competence is based on more than 50 years of experience in machine and plant design.The information gained during this time has been directly and consequently transferred into our engineering language. Neumag's engineering covers all areas for the formation of the plant, the continuous operation of the plant as well as contractual guarantees for the product quality and the performance of the plant.
The turnkey project management includes basic as well as detailed engineering: • mechanical engineering • process and civil engineering • piping and air conditioning • measurement and control engineering • electrical and instrumentation engineering
The utilization of the high functionality of the current data base, 3D-CAD software and the networking with SAP and CAD, secures a highly efficient state-of-the-art preparation of the documents.
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ГУРосНИИИТиАП Ассоциация МВТК
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2008 год
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