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Advantages and disadvantages of SMS non-woven fabric online compounding process
by：Sunshine
2021-04-02
In the production process of SMS non-woven fabrics, according to the general classification method, it can be divided into two process routes: online compounding and off-line compounding. But now there is a new composite method, that is, the hot rolling method is used to composite spunbond and meltblown on the meltblown line, because this method has the same characteristics as on-line composite and off-line composite, but also differs Because of the characteristics of online compounding and off-line compounding, it is recommended that the classification of SMS non-woven fabrics is basically divided into three categories: on-line compounding, off-line compounding and meltblown hot-rolling compounding. These three processes are discussed below.
Online compounding process
Online composite process definition
On-line compounding is SMS non-woven fabric compounding that can be achieved through spunbonding and meltblown equipment on the same production line, the so-called one-step SMS non-woven fabric (on-line compounding). SMS non-woven fabrics are spread on a moving mesh curtain to form spunbonded, meltblown, and spunbonded composite fiber layers, and then thermally bonded through a hot rolling machine, and finally through a winding machine to form SMS non-woven non-woven fabrics cloth.
SMS non-woven fabrics make full use of the advantages of spunbond and meltblown technologies. The spunbond layer increases the strength and wear resistance of the product, and makes up for the weakness of the low strength of the meltblown fabric. The meltblown spinning fiber reaches 1～4μm, can improve the uniformity and barrier properties of the product, and can make up for the poor uniformity of spunbonded nonwovens.
Advantages of online compounding process
The production of SMS non-woven fabric by one-step on-line composite process has the following advantages.
(1) According to the performance requirements of the product, the structure ratio of the spunbond layer and the meltblown layer can be flexibly adjusted to ensure that the product has good air permeability under the condition of high hydrostatic pressure resistance;
(2) Since the structure ratio of the spunbond layer and the meltblown layer can be flexibly adjusted, in the fierce market competition, it is beneficial to reduce costs and occupy a favorable position;
(3) It can produce products with very small weight, for example, it can produce SMS non-woven products of about 10g/m2;
(4) The product has good uniformity and a good overall appearance;
(5) The hand feels soft, if fine denier S is used, the SMS non-woven fabric produced will have a softer hand and better comfort;
(6) The product has high hydrostatic pressure resistance and filtration performance, which is especially suitable for medical and health applications;
(7) High production speed and large output. For example, the SM-MMS production line provided by Reifen has an output of 18000t/a and a maximum mechanical speed of 600m/min;
(8) Suitable for large orders, the advantages of online compounding are fully utilized.
Disadvantages of online compounding process
On-line composite technology also has its weaknesses, mainly in the following aspects.
(1) The investment is large, and the investment of 1 SMMS production line is about 200 million yuan;
(2) The construction period is long, and the equipment manufacturing time is long. The equipment manufacturing cycle of a SMMS production line is about 10 months, and the installation and commissioning takes more than 10 months. Basically, you can say this. The online composite SMS non-woven production line takes nearly two years;
(3) On-line composite products are basically shaped for thin products, with a weight of about 10～70g/m2. If thick products are to be produced, the weight of M must be increased, so that the output of S will be sacrificed. . For example, on-line SMXS production line, because the output of meltblown is too much different from that of spunbond, the production line is mainly suitable for producing products with only 2～3g/m2 of meltblown content, which limits the increase in the speed of the entire production line. If products with a thicker meltblown layer are produced, the production speed will be greatly reduced. Therefore, a melt-blown head was added to the original X position to form an SMMS production line, which increased the production speed, increased the output from the original 9,000t/a to 12,000t/a, and increased the economic benefits of the enterprise. Adding meltblown spinning heads is the solution to output matching, but SMMS or multi-M arrangement will increase the investment cost, and at the same time make the production line less flexible in production. This is very contradictory to the current situation of my country's spunbonded nonwovens and the characteristics of the product market in multiple fields.
(4) Because S and M use different raw materials, the diameter and length-to-diameter ratio of the spinneret holes are different, so in production, the melt nozzle is easily blocked and the replacement frequency is significantly higher than that of the spunbond process. The hole blocking phenomenon is more serious when cloth, and will cause the S and M die heads to not be replaced at the same time, which has a great impact on normal production. Especially when producing dark color SMS non-woven products, this phenomenon is more serious, which forces manufacturers to have strict requirements on meltblown raw materials.
(5) On-line composite SMS non-woven production line, the distance between the meltblown die head and the web forming machine can be adjusted, but the angle between the mesh curtain of the web forming machine and the meltblown die head cannot be adjusted, which affects Adjust the air permeability and uniformity of SMS non-woven products.
(6) On-line composite SMS non-woven fabric production line, due to the many spinning dies, so when the production color is changed, more transitional fabrics will be produced, which is not conducive to reducing costs and improving economic benefits.
(7) The online composite production line is especially suitable for large production orders, but it is difficult to adapt to small production orders.
Online compounding process
Online composite process definition
On-line compounding is SMS non-woven fabric compounding that can be achieved through spunbonding and meltblown equipment on the same production line, the so-called one-step SMS non-woven fabric (on-line compounding). SMS non-woven fabrics are spread on a moving mesh curtain to form spunbonded, meltblown, and spunbonded composite fiber layers, and then thermally bonded through a hot rolling machine, and finally through a winding machine to form SMS non-woven non-woven fabrics cloth.
SMS non-woven fabrics make full use of the advantages of spunbond and meltblown technologies. The spunbond layer increases the strength and wear resistance of the product, and makes up for the weakness of the low strength of the meltblown fabric. The meltblown spinning fiber reaches 1～4μm, can improve the uniformity and barrier properties of the product, and can make up for the poor uniformity of spunbonded nonwovens.
Advantages of online compounding process
The production of SMS non-woven fabric by one-step on-line composite process has the following advantages.
(1) According to the performance requirements of the product, the structure ratio of the spunbond layer and the meltblown layer can be flexibly adjusted to ensure that the product has good air permeability under the condition of high hydrostatic pressure resistance;
(2) Since the structure ratio of the spunbond layer and the meltblown layer can be flexibly adjusted, in the fierce market competition, it is beneficial to reduce costs and occupy a favorable position;
(3) It can produce products with very small weight, for example, it can produce SMS non-woven products of about 10g/m2;
(4) The product has good uniformity and a good overall appearance;
(5) The hand feels soft, if fine denier S is used, the SMS non-woven fabric produced will have a softer hand and better comfort;
(6) The product has high hydrostatic pressure resistance and filtration performance, which is especially suitable for medical and health applications;
(7) High production speed and large output. For example, the SM-MMS production line provided by Reifen has an output of 18000t/a and a maximum mechanical speed of 600m/min;
(8) Suitable for large orders, the advantages of online compounding are fully utilized.
Disadvantages of online compounding process
On-line composite technology also has its weaknesses, mainly in the following aspects.
(1) The investment is large, and the investment of 1 SMMS production line is about 200 million yuan;
(2) The construction period is long, and the equipment manufacturing time is long. The equipment manufacturing cycle of a SMMS production line is about 10 months, and the installation and commissioning takes more than 10 months. Basically, you can say this. The online composite SMS non-woven production line takes nearly two years;
(3) On-line composite products are basically shaped for thin products, with a weight of about 10～70g/m2. If thick products are to be produced, the weight of M must be increased, so that the output of S will be sacrificed. . For example, on-line SMXS production line, because the output of meltblown is too much different from that of spunbond, the production line is mainly suitable for producing products with only 2～3g/m2 of meltblown content, which limits the increase in the speed of the entire production line. If products with a thicker meltblown layer are produced, the production speed will be greatly reduced. Therefore, a melt-blown head was added to the original X position to form an SMMS production line, which increased the production speed, increased the output from the original 9,000t/a to 12,000t/a, and increased the economic benefits of the enterprise. Adding meltblown spinning heads is the solution to output matching, but SMMS or multi-M arrangement will increase the investment cost, and at the same time make the production line less flexible in production. This is very contradictory to the current situation of my country's spunbonded nonwovens and the characteristics of the product market in multiple fields.
(4) Because S and M use different raw materials, the diameter and length-to-diameter ratio of the spinneret holes are different, so in production, the melt nozzle is easily blocked and the replacement frequency is significantly higher than that of the spunbond process. The hole blocking phenomenon is more serious when cloth, and will cause the S and M die heads to not be replaced at the same time, which has a great impact on normal production. Especially when producing dark color SMS non-woven products, this phenomenon is more serious, which forces manufacturers to have strict requirements on meltblown raw materials.
(5) On-line composite SMS non-woven production line, the distance between the meltblown die head and the web forming machine can be adjusted, but the angle between the mesh curtain of the web forming machine and the meltblown die head cannot be adjusted, which affects Adjust the air permeability and uniformity of SMS non-woven products.
(6) On-line composite SMS non-woven fabric production line, due to the many spinning dies, so when the production color is changed, more transitional fabrics will be produced, which is not conducive to reducing costs and improving economic benefits.
(7) The online composite production line is especially suitable for large production orders, but it is difficult to adapt to small production orders.
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