Fleissner High-end fibres by compact spinning - CREON High-end fibres by... · by Compact Spinning Erwin Glawion Coordinator of Technological Innovations ... Total output 10 to 60

High -End Fibersby Compact Spinning

Erwin Glawion

Coordinator of Technological Innovations

Fleissner GmbH

Phone: +49 - (0)6103 - 401 – 409Fax: +49 - (0)6103 - 401 – 440E-mail: [email protected]: www.fleissner.de

Better machines. Better Fibers.

Moscow 12. February 2008

28.05.2012 Fleissner GmbH 2

Company profile

Fleissner headquarters Egelsbach / Germany

Fleissner GmbH

Founded in: 1848

Turnover 2007: > 50 Mio. €

Global workforce: 300

Fields of activity: Complete systems & individual machinery for nonwovens, man-made fibers, carpet & textile lines


Company profile

Tradition and technical milestones of Fleissner

1848: Founded by Johann Christian Fleissner in Asch/Bohemia as blacksmith‘s shop

1929: Hans Fleissner receives first patent for Through Air Dryer

1951: Family Fleissner moved to current location in Egelsbach with growing reputation as textile machinery supplier

1960: Worldwide leading supplier for man-made fiber lines

1975: Development of machines for the Nonwovens production

2006: Trützschler acquires Fleissner GmbH


Tradition & Innovation

ITMA 2007

Impressions

Company profile


Company profile

Technical Centre in Egelsbach

Water-entangling

System

AQUAJET

Conventional and compact spinning

with complete draw line


Company profile

Manufactured by Fleissner

Drums

Draw

stands

Drier

Rolls


Company profile

Products made on Fleissner machinery

Man Made Fiber

Paper / Tissue

Textile / Carpet

Nonwovens


High -end fibers

Colorfast & uniformity

Low shrinkage

Some fiber applications and their requirements

Bulk & resilienceCotton-like

High -endfiber


52%

21%

17%

9% 1%

Fibers

Films

Bottles

Straps

others

Applications of bottle flakes in Europe

Source: PETcore/PCI 2007

High -end fibers


Crimp & bulk

free ofdefects

elongation& tenacity,shrinkageColor

matching&uniformity

High-endfibres

Rawmaterial

costs

High -end fibers

Balance of raw -material and fiber quality

Rawmaterial

costsCrimp & bulk

free ofdefects

elongation& tenacity,shrinkageColor

matching&uniformity

High-endfibres

Quality


Raw material qualitylow

high

fiber

sta

ndar

d le

vel

lowhigh

Cotton type 1,4 dtex

Fill fiber 6,7 dtex

Carpet fiber 17 dtex

Nonwoven fiber 3,3 dtex

Productivity

Investment costs

Chips virgin chips recycled bottle flakes straps fiber waste

High -end fibers

Discrepancy of fiber production


Material handling ( Drying, dosing)

Melt preparationMelting, Homogenizing, Filtration

Melt distribution (Pipes, beam)Fiber formation (Quenching, spin finish application

Polymer/melt part

Drawing

Texturing/ Crimping+Heat setting

Winding/ Cutting+Baling

Textile part

Basic process steps of fiber spinning

Technological basics



10 100 1 000 10 000 100 000

Number of holes per spinneret1

1000

2000

3000

4000

5000

Spi

nnin

g sp

eed

(m/m

in)

Spinning processes for fibers and filaments

FilamentsFDYPOYBCF… Staple

1-stepStaple2-step


Influence of quenching and number of rows of holes

Quench

Que

nch

tem

p. high

low

Isotherms

backfront

Low dpf = many rows

High dpf = few rows

draw

abili

ty



Up to 300 m/minUp to 200 m/minFiber line speed

10 to 60 (100) tpd10 to 60 tpdTotal output

1,5 – 6,8 cN/dtex1,5 – 5 cN/dtexTenacity

1.000 – 6.0008.000 – 70.000Holes per spinning plate

1.000 – 1500 m/min

30 – 60 m/minSpinning speed

conventional plant (two-stage)

compact plant (single-stage)

160 – 260 kg/h80 – 200 kg/hTypical output per spinning position depending on dpf

0,8 – 30 dtex1,5 – 30 dtexTiter range

2, 3, 4, 6, 8, 12, 163, 4, 6, 8, 12, 16Spinning positions

Typical values for PET staple fibers



Cryst./ Drying

Melt preparation

Melt distribution

Fiber formation

Drawing

Crimping

Heatsetting

Cutting

Baling

CompactCompact

Can creel

Cryst./ Drying

Melt preparation

Melt distribution

Fiber formation

Drawing

Crimping

Heatsetting

Cutting

Baling

Tow plaiter

Conventional

Staple fibers by…



Lower investment

Less personnel

Less space

High flexibility

Ideal for melt-dyeing!

More economicalfor low dpf

Ideal for hugecapacities

Much cheaperspin packs forbicomponent

Staple fibers by…

Conventionalspinning

Compactspinning



Bulk [%]

Tenacity [cN/dtex]

Capacity compact [kg/h]

Capacity conventional [kg/h]

Trends of crimp and bulk vs. fineness

Single Titer [dtex]diameter [µm]4032271510

17116,73,31



10 20 30 40 50 60

Ten

acity

cN/d

tex

7

6

5

4

3

2

Conventionalline two-stage

Compact linesingle-stage

Fiber types by tenacity and elongation

Elongation (%)

wool type normal

viscose type

HM/HT cotton type



mas

terb

atch

L

b

a

optical testing

refe

renc

e

spinning drawing ?Conventional

spinning + drawing

Compact



Defects, undrawn fibers and fiber fusions after drawing

Most typical problem



Filament breaks with

wraps on thedraw stands

Most typical problems



MELT FIBER

Defects and fiber fusions after drawing

Filament breaks inspinningNormal

viscosity

Lowviscosity

The effect…



Wrapping fiber Drawing

amorphousfibers

Fiber fusions Crystallized fibers+ amorphous defects

… and the consequences on the draw line



+30%

-25%

0,003% H20Chewing

gum

honey0,2% H20

Influence of moisture on PET viscosities

Limit: ±5%!!




mmcmmkmLength of defect

mssminhrdaysweeksmonthsDuration of trouble

Flakes

Cryst./ Drying

Melt preparation

Melt distribution

Fiber formation

Drawing

Crimping

Heatsetting

Cutting&Baling

No influence

Defect analysis


Hopperdrier

Twinscrew

Processing time for different drying methods

1 hour1 min1 sec 1 day

Vacuumreactor


Dwell time

Tumbledrier


Ideal drier

Inadmissibledistribution

Sha

re o

f con

tent

[%]

Dwell time variation

Residence time distribution for different drying method s


Gauss Real time


Correlation between Fiber dia and viscosity

Viscosity (Pas)

Fiber dia (µm)

time (ms)

High peak

Low peak



Tumble drier


Drawbacks:-Space-Manpower-Investment costs-Batch process with risksduring emptying and bysucceeding conveying

Advantages:-Low energy consumption-Perfect quality



Vacuum reactor

Advantages:-Low energyconsumption-Little space

Drawbacks:-Wear parts-Investment costs-Wide dwell time spectrum



Twin Screw Extruder

Drawbacks:-Sensitive process withcomplicated pressurecontrol

Advantages:-Low energy consumption-Minimum space



Barrier layer effect

„cold“ flakes withhigh moisture

„hot“ flakeswith

low moisture

Drier with core flow

Hopper drierAdvantages:-Low investmentcosts-High quality

Drawbacks:-High energy costs-Wide dwell time spectrum withoutflow optimization


Solutions

Barrier layer effect

„cold“ flakes withhigh moisture

„hot“ flakeswith

low moisture

Flow-optimized drierDrier with core flow

Hopper drier


Solutions

Flakes

Melt distribution

Fiber formation

Cryst./ Drying

Melt preparation

Filt

ratio

n

Dos

ing

Ext

rusi

on

TRADITIONAL


Solutions

Flakes

Melt distribution

Fiber formation

Melt preparation

Filt

ratio

n

Dos

ing

Ext

rusi

on

Met

erin

g

Deg

assi

ng

TWIN-SCREW


Solutions

Flakes

Melt distribution

Fiber formation

Crystallizer

Melt preparation

Filt

ratio

n

Dos

ing

Ext

rusi

on

Met

erin

g

Deg

assi

ng

TWIN-SCREW


Solutions

Flakes

Melt distribution

Fiber formation

Vacuum reactor

Melt preparation

Filt

ratio

n

Dos

ing

Ext

rusi

on

Met

erin

g

Deg

assi

ng

SINGLE SCREW


Very longVery shortVery shortVery longColor changing time

Medium to low

Medium to high

Medium

Medium

Twin Screw Extruder(with crystallizer)

Low

Medium

Medium

Very short

Twin Screw Extruder(without crystallizer and drier)

High to Medium

Reasonable

High to low(depending on drier)

Long

Single ScrewExtruder(with drier and crystallizer)

LowEnergy costs

MediumTime for Drying

Very lowChance to getviscosity variationsfrom drying

Single ScrewVacuumExtruder(with vacuumreactor)

HighInvestment volume

Pressure sensivity Low High High Medium

Solutions

Comparison of extrusion systems


Further features of Fleissner compact spinning plant

1. Quick color change => central melt distribution

Solutions

2. Uniform temperature distribution =>

Dowtherm heating

3. Melt homogenization => sand filtration

4. Uniform drawing conditions =>outflow quench

5. Easy handling => Quick bottom loading(Zimmer-design)

6. Minimized fiber wrapping => optimized spin

finish application


Minimization of influence of pressure variations

<1

Rotary typePiston type

Solutions

PMT

Piston type

Rotary type


3,7 - 4,2

3,4 - 3,7

3,0 - 3,4

Max. TenacitycN/dtex

40 – 602

60 – 801

80 – 1001

Min. Elongation%

Draw Frame 3

Draw Frame 2

Draw Frame 1

Draw Zones

Post treatment on draw line

2

Examples of draw line configurations


Post treatment on the draw line

Finish applicator

CompactSpinning line

Draw zone with steam duct

View on draw line with 1st drawing section


Post treatment on the draw line

Heatsetting Crimper Tow Stacker Finish applicator Draw stand

View on draw line with crimper section


Summary

- Compact spinning is ideal for the recycling of bottle flakes

- Compact spinning is the best process to produce coarse and/or melt-dyed high-end fibers especially for the automotive industry

- Defects and fiber wrapping can only be avoided or eliminated by suitable hardware components

- Twin-screw extruders in combination with rotary screens are the best technological choice

- Fleissner has the technological know how to be a competent supplier and partner for fiber manufacturers


Thank youfor your

attention .Our representative: Textima GmbH

Phone: +49 – (0)30 24004 160Mobile: +49 – (0)172 3868 448E-mail: [email protected]

[email protected]: www.fleissner.de

Documents

Fleissner High-end fibres by compact spinning - CREON High-end fibres by... · by Compact Spinning Erwin Glawion Coordinator of Technological Innovations ... Total output 10 to 60