Man Made Fiber Production
& Spinning Process
Module 2
Forms of Man Made fiber
MMF are produced in three types –
1. Filament
2. Staple
3. Filament tow
1. Filament
Continuous length.
Filament fibers are spun through spinnerets with 350 holes or fewer, which
determines the size of the yarn produced. The number of holes in the spinneret
determines the number of filaments that will make up the yarn.
Filaments can be categorized into two types:
1. Monofilament: Made from a single filament of fiber.
2. Multifilament: Made from multiple filaments twisted or combined together.
2. Staple Fiber
oStaple fibers are relatively short and have a defined, limited length.
oThese fibers are typically created from filaments spun through large
spinnerets, which may have up to 3000 holes.
oThe length of the staple fiber is determined based on its intended
application.
oStaple fibers are generally at least 100 times longer than their diameter.
3. Filament Tow
oContinuous filaments drawn loosely together.
oUsed to produce staples by breaking or cutting.
oUp to 1,00,000 filaments.
Differentiate between Natural fiber & Man Made fiber
Natural Fiber Man Made Fiber
The fiber which we get from nature is called The fibers made by regeneration system
natural fiber
Number of molecular weight is not limited Limited
Hygienic materials made from natural fibers Not always hygienic
Comfortable to wear Uncomfortable
It cannot be made as our expected form It can be made
The number of molecules controlled by The number of molecules controlled by
nature human
Dependent on climatic condition Independent production from climatic
condition
Properties required for Fibre forming polymer
oHigh molecular weight is preferred.
oHigh crystallinity is not suitable.
oResistance to various chemicals is required.
oOrientation should exhibit both physical and chemical symmetry.
oStraight-chain structure is desirable.
oGlass transition temperature (Tg) should be close to room temperature.
oCrystalline melting point (Tm) should range between 200°C and 300°C.
oSolubility in at least one solvent is necessary for spinning.
oHygroscopic nature should be hydrophobic.
Chemical Spinning
Man made fibers are produced by converting the fiber forming substance
to a viscous fluid that is extruded through the holes of a spinneret and
then solidified by coagulation or evaporation or cooling. This process is
known as chemical spinning.
Methods of Production
Spinneret
oSimilar to a shower head.
oStainless steel or precious metal alloys e.g. nickel, platinum, gold,
titanium, vanadium etc.
oCorrosion resistant and withstand high pressure.
Control of Filament Diameter
oEqual hole dimensions are maintained.
oBreakage or clogging of holes are prevented
Filtration and Cleaning
oSpinneret holes are very sensitive to impurities.
oThorough filtration of the fluid prior to spinning.
oSpinnerets are cleaned at regular intervals.
Spinneret Holes
oFor melt spinning (1st image), a spinneret hole may be of 0.1 mm diameter.
oFor wet spinning (2nd image), the hole size is much smaller with large
number of holes.
oFor dry spinning (3rd image), holes are widely spaced so that evaporation of
the solvent can be faster.
Features of a Spinneret
1. Tapered Hole Design: Spinneret holes are slightly wider at the entry
than at the exit.
2. Filament Denier: The denier of the extruded filament does not solely
depend on hole size but is influenced by melt delivery speed.
3. Specialized Spinnerets: Specific spinnerets are required for
producing hollow fibers and bicomponent fibers.
4. Maintenance Requirement: Over time, spinnerets require inspection
and cleaning to maintain efficiency.
5. Potential Defects: Spinneret holes may develop blockages or
breakages with prolonged use.
1. Melt Spinning
Basic Principle
oUsed for polymers that can be
melted safely (Td – Tm ≥ 30°C).
oMolten polymer is pumped
through a spinneret which
subsequently gets cooled and
solidified.
Td = Decomposition Temperature
Tm = Melting Temperature
Melt Spinning
Cross sectional Shape of Fibers
oMelt spun fibers can be forced
through the spinneret in different
cross sectional shapes which give
different qualities to the fabrics.
oFilaments are of compact structure
with smooth surface.
Industrial Machines
Features and Characteristics
1. Simple and less expensive technology
2. Filaments with all possible cross-sections can be produced
3. No toxic hazards
4. Solvent not required, no purification problem
5. Highest speed (up to 10,000 m/min)
6. Not suitable for thermally unstable polymer
Typical Melt-spun Fibers
1. Polyester
2. Polyamide
3. Polypropylene
4. Polyethylene
5. Glass
2. Dry Spinning
Basic Principle
oUsed for polymers that need to
be dissolved in a volatile solvent.
oHot air/gas is used to evaporate
the solvent to get the solid fiber.
Dry Spinning
Cross sectional Shape of Fibers
oDry-spun fibers usually have
deformed cross sectional shapes.
oThe filaments are of microporous
structure with compact surface.
Industrial Machines
Features and Characteristics
oDry spinning is used in cases where the polymer may degrade
thermally if attempts to melt.
oThe process necessarily introduces another species and its removal
causes the cost to rise.
oThe cost can be minimized by using an efficient solvent recovery
system.
oFilament solidification takes place faster on the external layers and
slows down towards the interior.
oAs a consequence of mass exchange, the original round filament
undergoes a contraction generating a deformed cross-section.
Features and Characteristics
oCumbersome technology
oFlammable and toxic solvent hazards
oYarn does not require purification
oMedium speed (up to 1,500 m/min)
oSolvent recovery system must be used
Typical Dry-spun Fibers
1. Acrylic
2. Modacrylic
3. Acetate
4. Triacetate
5. Elastane/Spandex
3. Wet Spinning
Basic Principle
oUsed for polymers that have to
be dissolved in a non volatile
solvent.
oThe spinneret is immersed in a
chemical bath that precipitate &
solidify the fiber.
Industrial Machines
Features and Characteristics
1. Cumbersome technology
2. Environmental pollution hazards
3. Purification of the filaments required
4. Slow speed (up to 500 m/min)
5. Suitable for tow production combining all operations
6. Solvent and chemical recovery system may be used
Typical Wet-spun Fibers
oAcrylic
oModacrylic
oViscose
oElastane/Spandex
oAramid
oCarbon
oModal
oCupro & Lyocell
4. Gel Spinning
Basic Principle
o Used for high strength fiber through
a gel state as intermediate.
o Extruded solution is cooled down by
a gas or a liquid medium.
o During extrusion, the polymer chains
are bound together at various points
producing strong inter chain forces
that can significantly increase the
strength of fibers.
Features and Characteristics
1. Gel spinning produces fibers with exceptional tensile strength suitable for
high-performance applications.
2. The polymer is dissolved in a solvent to create a gel-like substance for
extrusion.
3. Gel spinning occurs at lower temperatures, reducing energy consumption
and material degradation.
4. Allows better control over polymer molecular weight, enhancing fiber
properties.
5. Results in highly oriented fibers, improving strength and stiffness.
6. The method can have a lower environmental impact, especially with
proper solvent recovery.
Typical Gel-spun Fibers
1. UHMWPE
2. Aramid
3. PVA
4. PAN
Production advantages of manmade fibers over natural fibers
1. Ready Accessibility of Raw Materials: Manmade fibers benefit from the readily available raw
materials like wood pulp and petrochemicals, ensuring a stable supply.
2. Stability of Market Price: The price of manmade fibers tends to be more stable, free from sudden
fluctuations seen in natural fiber markets.
3. Independence from Climatic Conditions: Manmade fiber production is not dependent on seasonal
or climatic changes, unlike natural fibers that rely on weather and agricultural conditions.
4. Higher Labor Productivity & Machinery Efficiency: Manmade fiber production is more efficient,
leading to greater labor productivity and machinery efficiency, resulting in cost savings.
5. Uniform and Constant Fiber Qualities: Manmade fibers offer consistent and uniform qualities such
as fiber length, fineness, and strength, which are difficult to achieve with natural fibers.
6. Control Over Fiber Parameters: The production process of manmade fibers allows for precise
control over various fiber parameters, such as texture and thickness.
7. Limited Use of Water and Insecticides: Manmade fiber production typically requires less water
and fewer insecticides than growing natural fibers, reducing environmental impact.
Thank
You