How to produce nonwoven fabric with fillers by nonwoven fabric machine to increase the benefits of nonwoven fabric production in Mexico?
In nonwoven production line, commonly used auxiliary materials (additives) include color masterbatch, functional masterbatch, filler, etc.
Filler is an additive widely used in plastic, rubber, film, fiber and other fields, which has a good effect on changing the properties of these materials, saving raw materials and reducing production costs.
With the rapid development of nonwoven fabric industry, in order to increase competitive advantage and reduce production costs, in recent years, enterprises in the nonwoven fabric industry have reduced the amount of PP chips by adding fillers to raw materials, so as to achieve the purpose of reducing nonwoven product costs.
The filling masterbatch is composed of carrier polymer and filler. The carrier polymer should be the same type of polymer as the main raw material.For example, when used in PP nonwoven fabric production line, the carrier polymer filled with masterbatch should also be PP. Since the price of the filler added is far lower than that of the carrier polymer, the price of the filler masterbatch will be lower than that of the carrier raw material.
The main purpose of adding fillers to nonwoven fabric is to reduce non-woven production costs, which are generally only used in the production of spunbond nonwoven fabric.
For example, when the price of spunbond PP chip raw material is USD1846.5 / T, the average price of filling masterbatch is only about USD987/ T. after adding fillers, greater economic benefits can be obtained.
However, the addition of fillers into the melt, especially in the case of a large proportion, will have a significant negative impact on the product quality.For some nonwoven fabric used in medical and health fields, if the purity of fillers is not high, silicon, iron and other elements and harmful heavy metals will affect the safety of products.
Taking the commonly used calcium carbonate filler(CaCO3)as an example, after adding this masterbatch, the heat resistance of the product can be improved, the rigidity and wear resistance of the product can be increased, the processing performance can also be improved, and the dimensional stability of the product can also be improved.But at the same time, it will increase the density of the product. Compared with the product without filler, the same amount of product becomes thinner, and the impact toughness of the material decreases, and the breaking strength and elongation become smaller.
Therefore, in production activities, it is necessary to confirm the feasibility of using fillers according to the purpose of the product, as well as the actual process used and the proportion that can be added. The greater the addition proportion, the more obvious the impact on product performance.The general requirements for the filling masterbatch are: the particle size and distribution of the filler should be appropriate. Too large particle size is easy to block the filter device and spinneret hole of the melt filter and affect the performance of the product.
The general technical requirements for filling masterbatch are as follows:
1.Particle size: φ 2.5mmx3mm～ φ 3mmx4mm, uniform size, no more than two continuous particles are allowed, and the quantity proportion of two continuous particles shall be limited to no more than 0.2%.
2.Appearance: the surface is bright and clean, and the color is white and opaque. The higher the whiteness, the better.
3.Density: 1.6 ~ 1.8g / cm3.The density of the filler masterbatch is related to the type and proportion of filler used (for example, the density of calcium carbonate is 2.71g / cm3;The density of kaolin is 2.6g / cm3; The density of talc powder is 2.75g / cm3; The density of mica powder is 2.9g / cm3; The density of wollastonite is 2.9g / cm3).
4.Melt flow index: 30 ~ 50g / 10min (for powder raw materials), 50 ~ 70g / 10min (for granular raw materials).
5.Pressure filtration value (DF value): not higher than 0.2pa · C ㎡ / g.
6.Moisture content: less than 0.25%, the less the better.
7.Ash content: less than 0.02%, the less the better.
8.There is no pungent smell, and the content of heavy metals should meet the requirements of relevant technical standards.
9.Dosage: 10% – 35%. The specific addition proportion should be determined according to the performance of the equipment and the purpose of the product. The larger the dosage is, the lower the production cost of the product is, but the greater the impact on the performance of the product is.
The important reason for the rapid development of PP spunbonded non-woven fabric is its simple and fast manufacturing method, low product cost, stable quality, and strong market competitiveness. In order to reduce the use of polypropylene and reduce carbon dioxide emissions, producers also add calcium carbonate filling masterbatch during the production process, giving it more advantages in terms of price, processing, production costs, physical indicators, and other aspects.
