The production of staple fibers is based on the extrusion and spinning of many continuous filaments of a specific size (titre in den or dtex). These filaments are collected into a large bundle (tow) which can include more than one million filaments. The tow is subsequently drawn, crimped, and cut into fibers of determined length. This specific line has only a few years in production and comes also with some of the elements as brand new.
Type: PP extrusion
Year 2001-2020
Power specs: 380 V/3 Phase/50 Hz
Average capacity 1000 kg/hr for HT fiber, higher output for non-HT fiber.
Specifications obtained for HT, average 50 cN/tex and 100% elongation.

Consisting of:
2*extruders:
– #1 – dia 200 mm with 312 kW DC motor
– #2 – dia 161 mm with 328 kW DC motor.
– Filter surface 2x 160 mm dia and 3 x 160 mm dia.

Spinning system:
– 9 positions, oil heated, PT100 T measuring system, pressure measurement for each position

Spin packs and spinnerets:
– 14 spin packs – dia 860 mm,
– 25 spinnerets with 10*75,000 holes, 8*65,000 holes and 7*45,000 holes
Cranes, loading system and pre-heating oven
Oil boiler – electrically heated
Air Quenching, 1 for 6 positions and 1 for 3 positions
Suction spinning exhaust smoke
Godets and waste collector
– Godet 1 – 7 rolls, dia 400*1000 mm, chromium plated, 60 kW DC motor, thermal oil heated
– Godet 2 – 7 rolls, dia 400*1000 mm, ceramic plated, 125 kW DC motor, thermal oil heated
– Godet 3 – 7 rolls, dia 400*1000 mm, ceramic plated, 250 kW DC motor, thermal oil heated
– Waste collection with 3 aspirators (1 after each godet) and waste container
Steam box and stacking rollers
– 3 stacking rollers, ceramic coated, 1 roll with load control
Annealing oven – thermal oil heating
2 crimping units
– ww: 160 mm, up to 2000000 denier and 2.5 – 8 crimps/cm
– ww: 200 mm, totally new – not yet installed
J-box

Cutting unit:
– cutter reels for 40, 45, 55, 70, 75 and 90 mm in aluminum and steel
Metal detection system
Ventilator
fully PLC controlled

Complete with:
2* BRAND NEW Zeppelin polymer silos (outside), Year 2020, each 223 m3, dia – 4050 mm, with level indicators (low/high) via paddle switch + radar sensor for each silo
AZO BRAND-NEW dosing and mixing system, Year 2020 with:
– 2 main dosing systems
– 3 gravimetric additive dosing system, tolerance 0.5-3%
– mixing unit for perfect homogenization
– including vacuum pumps
– separate control panel
Valvan BRAND NEW automatic bale press, Year 2020
– 40 tons pressing force
– to press for internal use, without packaging
– with PP cord banding
– capacity 1600 kg/hr.
BRAND NEW dry transformer, 2000 kvA, Year 2020
Daikin BRAND NEW cooling system, Year 2020
– 220 kW cooling capacity
– free cooling (dry cooler) in-line for energy saving
Pyrox BRAND NEW pyrolysis cleaning oven, Year 2020
– PLC control and afterburner
– up to 485 deg. C and afterburner up to 850 deg. C.
– can handle cart up to 1*1*1 meter
Alpha BRAND NEW ultrasonic cleaning bath, Year 2020
– 200 liters, internal dimensions 0.9*0.25*0.9 meters

Note:
Designed for PP extrusion of HT and non HT Fibers, Natural or Colored.

There are 2 extruder motors.
Extruder motor 1 with 3 heads are from 2001. Also, Godet 1/2/3, Crimper, Cutter,… Controls and automation also renewed.
Extruder motor 2 with 6 heads was a bit older but is fully renewed in 2011 (all new cabinets and etc).
Complete new AZO dosing system from 2021

The automatization is renewed with PLCs from Schneider in 2011. This for the complete line. Same for DC and AC drives (Parker / Eurotherm).
DC Motors and etc of the equipment are good maintained and refurbished, around 2001

All the other parts of the line, mechanical are from 2001.