STEP-1 Poy Spinning
Polyester Polypropylene chips are fed in the feeding
hopper with the help of electric hoist and are conveyed
from feeding hopper to DPG from where they are further
conveyed to the Storage Silos with the help of
compressed air. From the Silos, the chips enter the
blender for proper blending to avoid variation.
The chips, after blending, are stored in a Wet Chips
Hopper.
The level of chips in this hopper is automatically
controlled from where these are transferred to the
drying system through rotary air lock. Rotary air lock
does not allow the air to leak during the chips entry
from WCH to drying system. Dryer system dries the chips
with the help of hot air to control the moisture level
of the chips to make it suitable for spinning. From the
dryer, chips enter the Dry Chips Hopper before feeding
to the Extruder.
From the Dry Chips Hopper, chips are conveyed to the
extruder where chips are melted and mixed to give
homogenous molten polymer with the help of electrical
heaters. The same is thereafter filtered through
continuous polymer filter.
After filtration, the melt is distributed to 4 nos. of
spinning beams via manifold. The temperature of the
spinning beams and manifold is maintained by special
type of heat transfer media. Melt is purified by means
of metallic and sand filters before being extruded to
filament through spinnerets.
The extruder has a capacity to melt and deliver 800 kgs
of chips/hr. at high pressure upto 250 bars. Molten
polymer in spinning beam is extruded through the
spinnerets via polymer pump. The speed of polymer pump
is controlled by production computers to ensure uniform
flow of melt to produce quality of yarn. The speed of
polymer pump may be changed to produce different kind of
deniers.
Polymer melt passing through the spinnerattes comes out
in the form of yarn at a temperature of 280-290 °
C. The yarn is then cooled to solidify in the cooling
chamber and after the cooling, finish oil is applied to
yarn to lubricate the same for further processing. The
yarn is, thereafter, taken on the winder for winding on
paper tubes. The speed of the winder is controlled by
the computers and can be varied as per the process
requirement to produce different kind of deniers. The
POY thus produced is checked on automatic machines
called Tensorapid and Uster Tester-3 for checking of
thickness and uniformity properties.
STEP-2 Texturising
POY is thereafter transported from the POY department
to texturising section. It is then taken on creel and
fed to the texturising machines and heaters. After the
necessary heat setting and cooling, the texturised yarn
is collected on paper tubes and thereafter, packed in
corrugated boxes and sent to the market.
Polyester/ Nylon / Polypropylene chips are used for the
manufacture of respective Monofilament yarns. Chips are
dried in the case of Polyester to moisture level of 30
ppm before being fed to the extruder. This manufacturing
is a continuous process where chips are continuously fed
to the extruder through the dryer hoper. The extrusion
of the melt is done at 280 –290 ° C. The
controlled amount of molten polymer is fed to the Gear
Pump for delivery through nozzle. The operation of
delivery is widely known at Melt Spinning. Melt Spinning
is also done at 280-290 ° C. Molten monofilaments
are quenched in a water tank known as quenching bath.
Next, the solidified filaments are taken on godet 1 for
separation. The separated filaments are then taken on
the roll and separation is also done on godet 2,3, &
4. The monofilaments are stretched and drawn at high
temperatures between these godet rolls. Thereafter,
proper heat setting is done in order to make the
monofilaments dimensionally stable. These dimensionally
stable monofilaments are finally wound on the spools/
hasp winder.
