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Difference between Filament fiber and Staple fiber production process

Filament fiber production process

Dried chips are melted in an extruder before being quantified in a gear pump and transferred to a nozzle. Polymers are pushed through the tiny holes in the nozzle by heat and pressure, resulting in fiber, which is then cooled by cold air or water.

A single filament of mono filament is stretched to achieve various rigidity and elasticity. Stretching takes place at various roller speeds.The filament is then heat-treated to seal in the properties. Set amounts of filament are wound around bobbins and packaged. During packaging, a quality inspection takes place to set aside defective products.

Staple fiber production process

The base material, which comes in chips, is melted in an extruder before being quantified in a gear pump and transferred to a nozzle. Polymers that pass through the nozzle are cooled and solidified in a spinning tank, and end up in a fiber form (semi-finished product). Fiber released from multiple spinning tanks is lubricated and gathered before being wound by a gear wheel and placed in cans. Fiber placed in cans is given various properties through a stretching process, in which fiber is stretched at various roller speeds designed to endow different degrees of rigidity and elasticity.

The fiber is again lubricated for enhanced quality and to facilitate the processes that follow. A crimping process takes place to give the fiber various properties, including bulk and mixability. Moisture and lubricant on the fiber is dried off in a heat dryer. The fiber is then cut into required lengths and end up in a bale form. The fiber is then compressed, packaged, and stored for factory release when ordered.

Non-woven production process

Step 1: Choice of material: Nylon, Polyester, Polyolefin (PE/PP, PE/PET), Polypropylene

Step 2: Web formation: Carding, Air laid, Wet laid (Spunbond, Melt Blown, Flash spun)

Step 3: Web bonding: Needle punch, Spunlace, Thermal bond, Hot air-throught bond (Chemical bond, stitch bond)

Step 4: After treatment: Dyeing, Treatment

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