Spinneret

A plate or nozzle containing many fiber holes or slits through which a fiber
forming polymer solution is extruded in the fiber manufacturing process. The
number of holes varies with desired number of filaments required.

Made of:
-Platinum, Iridium, Stainless steel etc.
-Should be corrosion resistant metal.
Different shapes of spinneret
Features of Spinneret

► Spinneret holes are slightly wider at the entry than

the exit.
► The denier of filament extruded through a hole does
not depend upon its size, but it has some
significance on the efficient extrusion depending on
melt delivery speed.
► Special spinnerets are required for the production of
hollow fibres and bi-component fibres.
► After long use the spinnerets get checked and it is
essential to clean them.
Problems:
1. Breaking: on account of high temperature and
pressure.
2. Clogging: the holes can be blocked for the presence
of solid particle in the solution.

Remedies:
1. If spinneret breaks, they need to be changed.
2. For clogging, spinnerets needs to be changed
frequently.

Cleaning process:
1. Oven burnout method
2. Solvent cleaning method
3. Vacuum cleaner method
Flow chart of MMF production

1. Manufacture of the fiber forming polymer.

2. Spinning ( extrusion through spinneret)
3. Stretching/Drawing ( improving strength and crystallinity)
4. Texturing/Crimping ( developing natural fibre properties)
5. Intermingling( applied instead of twisting)
6. Heat setting( made dimensionally stable)
[Link] of the fibre forming
polymer
All man made fibres are composed of long chain molecules
known as polymer which are formed by chemical processing.
The polymer manufacturing process is the determining factor
for many basic characteristics such as density, melting point,
dyeing behavior, moisture absorption etc.
Common groups in polymers –
I)Amide or Peptide groups ( -CO-NH-)
II)Benzene ring
III)Ether linkage( -C-O-C-)
IV)Ester linkage(-C-O-O-)
V)Hydroxyl group (-OH)
VI)Nitrile group (-C-N-)
[Link]:

► 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.
► Wet spinning.
► Dry spinning.
1. 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.
Fiber: Nylon, polyester, and polyolefin fibres.
Working process

► The polymer in the form of hot molten material is forcely fed to the
spinneret.
► In the way to spinneret , the solution is purified by filter.
► Thus the filaments are extruded from spinneret .
► At last the filaments are strengthened by coolant air to solid form.
► Finally we get undrawn yarn for next subsequent process Drawing.
Requirements

► The polymer should not be volatile.

► The melting point of polymer should be less than
its decomposition temp.
Typical melt spinning

Polymer Melting point

Nylon-6,6 264 c
Nylon-6 220 c
PET 264 c
Polypropylene 167 c
Polyethylene 125 c
Advantage:

1. Can be used for both staple and continuous filament.

2. Direct and simple process.
3. No environment pollution.
4. No solvent required.
5. Non toxicity and no risk of explosion.
6. High production speed (2500 – 3000 ft/min)
Disadvantage:

1. Required more proper maintenance of the m/c.

2. For flat yarn separate stretching operation is reqd.
3. Heat of input is high.
 [Link] spinning
► In dry spinning, the fiber 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
fiber.
Dry spinning process:
► At first , the solid polymer & suitable solvent is dissolved together in the solution vessel
to form spinning solution which is forcely fed to the spinneret.
► In the way, it is purified by filter.
► Thus the filaments are extruded from the spinneret.
► At last, the filaments are strengthened to solid form by vaporizing the solvent by means
of hot air.
► Finally we get undrawn yarn for next process.
Process of Dry spinning
Advantage:
► Suitable for producing fine denier fibers.
► No need of wash of fiber.
Disadvantage:
► Investment cost is high.
► Toxic and risk of explosion.
► Heat input is very high.
► Can not be used for staple fiber production.
 [Link] spinning:
Wet spinning is the oldest process for spinning. In Wet spinning solution
of fiber forming material is extruded into a coagulation bath that causes
the stream to harden as a result of chemical or physical change.

The coagulation bath contains substance that is miscible with solvent but
do not dissolve polymer. The spinnerets are submerged in a chemical
bath and as the filament emerge, they precipitate from solution and
solidify.

Example: Cellulose (Viscose, Lyocell), Polyvinyl alcohol, Aramid, Spandex

etc.
Process:
1. At first, the solid polymer & solvent is dissolved in the solution
vessel to form the spinning solution which is forcibly fed to the
spinneret.
2. In the way to spinneret it is purified by filter.
3. Thus the filaments are extruded from the spinneret.
4. At last, the filaments are strengthened to solid form by extraction
of solvent instead of vaporizing used in dry spinning. The
extraction of solvent is done simply by washing it out or by
chemical reactions between the polymer solution & the reagent
in the spinning bath.
5. Finally, we get the undrawn yarn for next process.
Wet spinning Process:
Advantages & Disadvantages:

► Can be used for most polymers.

► Fibers or filaments can attain ► Washing and bleaching of fibres are
maximum strength. needed.
► Both organic and inorganic ► Sometimes toxic.
solvents can be used.
► Multiple bath may be required to
► Low temperature is required. complete removal of solvent.
► Investment cost is low.
 Subject Melt Spinning Dry Spinning Wet Spinning

Feed Polymers Polymer is fed in melt Polymer is fed in Polymer is fed in

form solution form solution form

Solidification Solidification is done Solidification is done Solidification is done

by passing cool air. by evaporating solvent by precipitation by
with hot air passing. passing through
coagulation bath.
Difference
End product Staple or filament Only filament Staple or filament
among Melt,
Productivity High High Low

Investment Cost Low High Low

Dry and Wet
Environmental Hazard Non Toxic Toxic (Risk of Toxic (Sometimes)
Spinning
explosion)

Heat required High Very High Low

Example Polyester, Nylon, Acetate, Triacetate, Aramid, Lyocell,

Olefin, Saran, Glass Acrylic, Modacrylic, Viscose rayon, Spandex
fiber etc. PVC, PVA etc. etc.
Dry Jet Wet Spinning:
- In dry wet spinning method, solution is extruded through spinneret which is suspended at short distance above
coagulation bath. Using this method it is possible to give higher stretch. Temperature of dope extrusion and
coagulation bath can be independently controlled.
- In system, where dope must be hot, to lower viscosity of dope to bring down to extrudable level and coagulation
bath to solidify the final filament, this spinning system is the only option.
- This method is extensively used for production of Aramid fiber.

Special
Spinning
Process

Fig: Dry-Jet-Wet Spinning

Fig: Wet Spinning vs Dry-Jet-Wet
Spinning
Gel Spinning:
- Gel spinning is a kind of dry wet spinning process which is used to obtain high
strength or other special fiber properties.
- Polymer is in GEL state, only partially liquid which keeps the polymer chains
somewhat together bound. These bound forms provide strong inter chain forces
in the fiber which increase tensile strength. They also have a large degree of
orientation of polymer chain contributing to make fiber stronger.
- Fibers are first passed through air and then cooled further in coagulation bath.
- Ex: high strength Polyethylene (Dyneema), High molecular weight Polyethylene
Special
(Spectra) etc are produced in this method.
Spinning
Process

Fig: GEL Spinning Method

Emulsion Spinning:
- This spinning process is used for those polymers which have very high melting
point and difficult to solubilize.
- Polytetrafluoroethylene [-CF2-CF2-] is a well known polymer for which emulsion
spinning method is applied.
- One example of such spinning is to mix Polytetrafluoroethylene with viscose to
obtain a spinning solution containing about 40% Polytetrafluoroethylene.
- For this example spinning is carried out in a coagulation bath containing sulfuric
acid, sodium sulfate and zinc sulfate.
Special
- Coagulation bath is suitable not only for viscose spinning but also for salting our
Polytetrafluoroethylene dispersion. Later at very high temperature (Approx 389
Spinning
degree celsius) is applied to flash off the cellulose.
- This method is used for preparing bio component fibers or filaments.
Process
- Example: Polyvinyl Chloride, polyvinyl Acetate etc.
Electro Spinning:
- Electro Spinning is a widely used method for the production of nanofibers.
- The process of electrospinning takes place among a spinning head where high
voltage is applied, syringe with metal needle and a rotating drum or static plate
working as a grounded nanofiber collecting counter electrode.
- Spinning solution is injected at a constant rate through spinning head which is
charged with high voltage (typically 5KV to 50KV)
- The applied high voltage difference between spinning head and ground results in Special
a nano to micron sized fiber jet which is drawn out at the opening of spinning
head. Spinning
- The solvent evaporates rapidly and under optimum condition a continuous
thread of nanofibers is deposited at the collector. Process
- Depending on the collection system, electrospun nanofibers are deposited either
in random fashion on the form of nano woven web/mat (in case of static plate
collector) or as parallelized nano fibers patches ( in case of rotating drum
collector).
Electro Spinning

Special
Fig: Electrospinning process Spinning
Process
 [Link]:

The process by which the yarn/ fiber is elongated by passing it

through a series of pair of rollers, each pair moving faster than the
previous one is called drawing. Drawing is always carried out in a
plastic condition. It is a system which removes weak and brittle
properties of filament.
Object:

I) To increase tensile strength of filament.

II) It orients the polymer molecules along the filament.
III) To reduce creep property.
IV) To increase orientation and crystallinity.
V) To remove brittleness and instability of the filament.
VI) Increase transparency and luster.
[Link]:
Texturisation is the process of introducing crimps, coils, loops or
wrinkles in the otherwise smooth continuous filaments. Synthetic
continuous doesn't have the same hairiness, warmth of handle or
absorbency that we get from yarns made of natural fibers.
About 85% Polyester produced worldwide are textured.

Basic Principle:
Texturisation is done in 3 steps:
- To heat yarn to plastic condition
- To impart the required shape of filament
- To cool it to retain the shape
Advantages & Disadvantages

► Crease resistance, dimensionally ► Create problem in laundering.

stable.
► Reduce strength.
► Better appearance, softer handle.
► Decrease abrasion resistance.
► Higher absorbency and better
► Creates hairiness of fibre.
perspiration conductivity.
► Better air permeability.
► More flexibility.
 [Link]:
The process by which two or more filaments are joined by use of additives or spot
welding or compressed air jet to produce a single intermingled yarn is called
intermingling.
There are 2 basic principles:
1. Spot welding by heat treatment or adhesive

2. Air jet compressed air at high pressure

 6. Heat Setting:
The process of imparting dimensional stability to fibre, yarns, fabrics or garments with
successive heating and cooling in dry and moist conditions is called heat setting.

Objects:
• To make the yarn, fabric, fibre
dimensionally stable.
• To remove shrinkage of fabric.
Disadvantage:
• The fibres become very stiff.
• Uneven shade due to uneven heat
set.
 Spin Finish is one of the most important part of Man Made fiber manufacturing
process.

It is an essential lubricating composition deposited on man made fibers to

reduce friction developed, as yarn passes over metal and ceramic machinery
surface.

Even natural fibers have their own spinning finishes in the form of wax for
cotton, sericin for silk, grease sterol for wool etc.

Functions: Spin Finish Application method:

1. Control of friction.
2. Reduction of static charge accumulation.
3. Cohesion of filaments Dipping
Roller
Spin Method

Finishes
Metere
d Finish
System
 A spin Finish should have good lubricity to reduce
coefficient of friction.
Should have antistatic properties.
It should provide balanced degree of cohesion, since too
much lubricity can cause slippage.
Should have good product stability.
Should not encourage bacterial growth.

Spin Finish
Desirable properties of a
Should have ability to wet fibers evenly.
Should not have any chemical effect on fibers
Should not get oxidized on prolonged storage
Should have suitable and controlled viscosity.
Should not have objectionable odor.
Should not cause corrosion to machine parts and should
not have dermatological effect of workers
Should be biodegradable and readily removable
Spin Should be available at reasonable cost

Finish
Morphology of chemical fiber:

Profile of fibers:
► Topography, fiber diameter, Cross section , fineness, Texture, amorphous- and
crystalline, semi-crystalline, lamellar crystals in a fibrous polymer.

Physical change:
► Strength , Elasticity , Plasticity , Porosity , Solubility , Swelling , Hydration ,
Capillarity.
S.N Name of the Instrument Measured Property
1 HVI (High Volume Instrument ) Fiber length, strength, fineness, color and trash
2 AFIS (Advanced Fiber Information Fiber length, trash and neps.
System )
3 X-Ray Diffraction System Amorphous and crystal part of a fiber.

Vibromate Individual strength of fiber

4 UV-Spectroscope Chemical composition & structures.

5 IR or FTIR-Spectroscope Chemical composition & structures with functional groups.

6 GPC Mass-molecular distribution

(Gel-Permeation-Chromatography)
7 DSC(Different Scanning Calorimeter) Thermal properties of fiber.

NMR Spectroscopy Structure of fiber

8 TGA(Thermo-Gravimetric Analysis) Thermal properties of fiber
9 SEM and AFM Surface topography of a fiber 39

10 Zeta potential meter Charge on fiber surface.