Man Made Fiber Spinning

Prepared By :

Prepared By : Mazadul Hasan sheshir

ID: 2010000400008
13th Batch (session 2009-2013)
Department : Wet Processing Technology
Email: mazadulhasan@yahoo.com
Blog : www. Textilelab.blogspot.com (visit)

Southeast University
Department Of Textile Engineering
I/A 251,252 Tejgaon Dhaka Bangladesh

right

Calssificatoin of fibres

Forms of Man Made fibre:

MMF are produced in three types

1. Filament:Filament fibres are spun from
spinnerets with 350 holes or less is
determined by the size of the yarn to be made
Monofilament: This filament is made only
of a single filament.
Multifilament: These filaments are made of
more than one filament.
2. Staple:Staple fibre is of limited and relatively
short length
3. Filament tow. An assemble of twist free
fibre.

Properties required for Fibre forming polymer:

Molecular weight should be high.

Crystallinity high not suitable.
Resistance to different chemical.
Orientation Physical and chemical symmetry.
Straight chain structure.
Glass Transition Temperature (Tg) Should be near to
Room Temp.
Crystalline Melting Point (Tm) - 200o 300o c is suitable.
Polymer should be soluble in some solvent from which it
can be spun.
Hygroscopic nature Should be hydrophobic

Synthetic Spinning System

 Spinneret: A nozzle or plate provided

with fire holes or slits through a fibre
forming solution or melt is extruded in
fibre manufacturing is called spinneret.
This is the most important part of a MMF
Spinner
producing m/c. The number
of holes,
sizes and shapes vary withetthe filament
desired.
Shape of holes:

Features of Spinneret:

Spinneret length: 10-25 mm

Spinneret diameter: 30-200 mm
Spinneret thickness: 3.0 mm
Hole dia: 0.1.-0.8 mm

Problems:
-Breaking (On account of high pressure and
temp)
Clogging (The holes can be blocked for solid
particles mix with polymer solution).

Remedies:
-For breaking problem: the spinneret is to be
changed.
-For clogging: the spinneret should be cleaned after
some days.

Number of holes in spinneret:

1. For monofilament: 1-3
2. For multifilament: 100-1000
3. Filament tow:up to 50,000

Flow chart of MMF production:

1. Manufacture of the fibre forming polymer.
2. Spinning ( extrusion through spinneret)
3. Stretching/Drawing ( improving strength and

crystallinity)
4. Texturing/Crimping ( developing natural fibre properties)
5. Intermingling/Interlacing( applied instead of twisting)
6. Heat setting( made dimensionally stable)
7. Cutting: According to requirements.

1. Manufacturing of the fibre forming polymer:

All man made fibres are composed of

long chain molecules known as
polymer which are formed by
chemical processing.
Common groups in polymers
Amide or Peptide groups ( -CO-NH-)
Benzene ring
Ether linkage( -C-O-C-)
Ester linkage(-C-O-O-)
Hydroxyl group (-OH)
Nitrile group (-C-N-)

Spinning:

The conversion of polymer into fibre is

called spinning. The fibre forming
substance is made temporarily fluid,
extruded through spinneret and then
returned to solid state (by
solidification) in fibre form.
Three types of spinning process:
Melt spinning (Synthetic).
Wet spinning.
Dry spinning.

Man Made Fiber Spinning Technology

SPINNING of polymers
There are typically three types of spinning for polymers: Melt, Dry and Wet.

Melt spinning (Fig. 1) is used for polymers that can be melted easily.

Dry spinning (Fig. 2) involves dissolving the polymer into a solution that can
be evaporated.

Wet spinning (Fig. 3) is used when the solvent cannot be evaporated and
must be removed by chemical means.
Melt spinning
In melt spinning the fibre-forming material is melted and extruded through
spinnerets, and the jets harden into solid filaments as they cool on emerging from the
spinneret. Nylon is a melt-spun fibre.
Dry spinning
In dry spinning the fibre-forming substance is dissolved in a solvent before the
solution is extruded. As the jets of solution emerge from the spinneret, a stream of hot
air causes the solvent to evaporate from the spinning solution, leaving solid filaments.
Acetate is dry spun by extruding acetone solutions of cellulose acetate into hot air.
Wet spinning
In wet spinning the solution of fibre-forming material is extruded into a coagulating
bath that causes the jets to harden as a result of chemical or physical change.
Viscose, for example, is wet spun. The solution of cellulose xanthate is extruded into
an aqueous solution of acids and salts, in which the cellulose is regenerated to form
solid filaments.

Man Made Fiber Spinning Technology

02. Spinning: Melt spinning:

The process of spinning by which fibre or

filament is produced from melted polymer
chips by extruding through spinneret
continuous filament produced here.
Number of filament depends on number of
holes in spinneret.
It is the most critical operation in the
production of nylon polyester, and
polyolefin, poly propylene fibres as number
of fibre properties such as uniformity,
crystallinity, and orientation are imparted
to the yarn during processing.

02. Spinning: Melt spinning:

Flow Chart
Feed

Melting

Metered extrusion

Cooling &
solidification by
cold air.

Moisture
conditioning

Lubrication
Yarn driving
Packaging

02. Spinning: Melt spinning:

Advantage:
Can be used for both staple and continuous
filament.
Direct and simple process.
No environment pollution.
No solvent required.
Non toxicity and no risk of explosion.
High production speed (2500 3000 ft/min)
Low investment cost.

Disadvantage:
Required more proper maintenance of the m/c.
Heat of input is high.

02. Spinning: Melt spinning:

Typical melt spinning:

Polymer
Melting point
Nylon 6, 6
264oC
Nylon 6
220oC
PET
264oC
Polypropylene
167oC
Poly ethylene
125oC

02. Spinning: Dry spinning:

In dry spgn, the fibre forming polymer

dissolved in a volatile solvent is
introduced into a heated drying
chamber where the solvent is
evaporated and solid fibre is obtained
through spinneret.
This process is used for Acetate and
some polyacrylonitrile fibre.

02. Spinning: Dry spinning:

Dry spinning solvent:

Fibre Solvent
I) Cellulose -Acetone + (2-6) % water
II) II) Triacetate -Methylene chloride
(40%) + Methanol (10%)
III) Poly acrylonitrile -Di-methyl
formamide or
Dimethyl acetamide.
IV) Spandex - DMF, DMAC.
V) Modacrylic - Acetone.

02. Spinning: Dry spinning:

Feed

Metered extrusion
Solidification by solvent

Evaporation

Lubrication

Yarn driving

Packaging

Dry spinning
Process

Dry spinning
Process

02. Spinning: Dry spinning:

Advantage:
Suitable for producing fine denier fibres.
No need of wash of fibre.

Disadvantage:
Investment cost is high.
Toxic and risk of explosion.
Heat input is very high.
Can not be used for staple fibre production.

Properties of solvent:
Solvent should not be volatile.
It should be organic.
It should have low boiling point.
It should be comparatively cheap.
It should be thermally stabilized.
It should be non toxic.

02. Spinning: Wet spinning:

In wet spinning a suitable solvent is used to

prepare fibre forming solution and another
coagulant is used in coagulating bath.
Solution is extruded through spinneret and in
contact of coagulant cellulose is regenerated.
Wet spgn solvent & coagulant:
Fibre Solvent Coagulant
Viscose Alkaline water
Dill H2SO4 + Na2SO4 +ZnSO4
PVA Water Aqueous NaOH
PAN DMF/DMC + Aq DMF/DMC + 40% ZnCl2

60% ZnCl2

02. Spinning: Wet spinning:

Coagulation
bath

Washing Bath

02. Spinning: Wet spinning:

02. Spinning: Wet spinning:

Advantage:
Suitable for staple fibre.
Both organic and inorganic solvent can be
used.
Low temp reqd.
Higher production due to continue spgn.
Softener process.
Investment cost is low.

Disadvantage:
Slow spgn speed.
Washing and bleaching of fibres are needed.
Toxic.

02. Spinning: Difference

Parameter

Melt spgn

Dry spgn

Wet spgn

1. Investment cost

Low

High

Low

2. Hazard

Non toxic

Toxic

Toxic

3. Heat of spgn

High

Very high

Low

4. Spinneret hole

2 many
thousands

300 900

20000 75000

5. Spgn speed

2500 3000
ft/min

2500 3000
ft/min

150 300 ft/min

6. Productivity

High

Low

High

7. Application

Filament or
staple

Filament

Filament or
staple

8. Solvent

Not required

Only volatile
organic solvent

Both organic and

inorganic solvent
can be use.

Comparative features of melt, dry and wet spinning

Features

Melt

Dry

Wet

Investment Cost

Low

High

Low

Hazard

Non-toxic

Heat of Spinning

High

Spinneret Hole

Spinning Speed

2 to many
thousand
2500-3000
ft/min

Toxic
(Risk of
explosion)

Toxic

High

Low

300-900

20,000-75,000

2500-3000
ft/min

150-300 ft/min

Advantage of man-made fiber technology:

Production does not depend on climate & location.
Quality & quantity can be controlled during production.
Length & thickness can be controlled as per requirement.
Staple length can be controlled as per requirement.
Smoothness and high luster.
Fiber processing is easier.
High productivity and low cost.

Disadvantage of man-made fiber technology:

1. Fabrics made of MMF are difficult to stitch.

2. Low air permeability.
3. Uncomfortable.
4. Unhygienic.
5. Hydrophobic.

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