Designed to accept model BKF rectangular spin packs.
Etched plates included for extrusion of concentric sheath/core filaments, eccentric sheath/core filaments, side by side filaments, and 16 pie filaments with round orifice spinneret orifices.
Additional etched plates provided for concentric sheath/core filaments, side by side filaments, and tipped filaments with trilobal orifice spinnerets.
Homopolymer filaments may be produced by using the same polymer in both extruders.
Other bicomponent cross sections can be produced with purchase of inexpensive spin pack components.
Spinneret Details
Two sets of spinnerets provided to spin solid, round filaments for desired denier range.
First set: ~2622 small round orifices; blocking plates reduce hole count to ~1311; maximum spun dpf range ~2.5–10.0.
Second set: ~1000 large round orifices; blocking plates reduce hole count to ~500; maximum spun denier range ~15.0–60.0.
Third set: 1000 trilobal orifices; blocking plates reduce hole count to ~500; maximum spun denier range ~12.0–45.0.
Actual processes and production rates depend on polymer selections and process development.
Polymer Handling
Polymer storage not included; customer supplies clean fiber grade chips.
Polymer A: main polymer; complete conveying, crystallization, drying, extruder feeding by customer.
Additive polymers: quantity 2, one per extruder; volumetric additive system.
Extruder throat split into rear and front chambers; additive chip metered at ~0.5%–5.0% of total flow into rear chamber.
Front chamber flood fed from customer's main polymer hopper; customer to coordinate extruder transition.
Metering by rotating bar with machined pockets; additive rate adjustable by motor-drive; drive automatically adjusted based on metering pumps in operation.
Includes vacuum loaded ambient hopper which flood feeds rotating additive feeder bar.
Additive drying available as an option.
Polymer B (PA, PET, CO-PET, PBT, and PE anticipated): polymer conveying, crystallizing, drying equipment supplied from Barr-Rosin or equivalent.
Two fluid bed crystallizer/column dryers for PET at 625 lb/hr at 3 hrs and 30 ppm final moisture plus CO-PET at 375 lb/hr using 24 hrs residence at 65°C for 50 ppm final moisture.
Two complete systems of fluid bed crystallizer/column dryers; each with vibratory inlet feeder/rotary valve, gas recycle system with cyclone, filter and heater, column dry air heater, flow meter and pressure control units, column level control system, discharge valve and connection to extruders.
Both columns sized for 4200 kg to give 24 hrs residence time at 375 lb/hr rating.
One set of control equipment for total plant: temperature controllers, level controllers, heater and feeder thyristors, chart recorder, mimic diagram and alarm system housed in separate control panel.
One ambient air dehumidifier unit: twin tower, sealed recirculation heat regenerative type; provides ~1000 Nm³/hr dry air at 50°C to the two columns; includes inlet and outlet air filters, pressure regulators, flow meters and distribution manifold; may be used for nitrogen drying without gas loss; features extended cooling cycles and water cooled heat exchanger on outlet to prevent heat spikes on CO-PET columns.
Two sets of vacuum conveying plant from storage units to inlet feeders of dryers; for nominal 10 m horizontal and 15 m vertical feeding distance; includes inlet suction unit and outlet cyclone separator and feeder hoppers; shut-off valve fitted above each feeder.
Ambient hoppers (carbon steel) with vacuum loaders included for processing some types of pre-dyed chips, polymers not requiring drying, and purge material.
Transfer Lines
Quantity 4, one assembly per extruder.
Dowtherm vapor heated with vaporizers included.
Vent stack assemblies included; customer to handle vented material.
Contains static polymer mixers as required.
Manifolds
Polymer A: quantity 2 (one per spinbeam assembly); conveys polymer A from transfer line to each spin position with equal residence time; heated with same Dowtherm vapor as polymer A transfer line; assembly may be removed without removal of spinning beam.
Polymer B: conveys polymer B from transfer lines to each spin position with equal residence time; heated with same Dowtherm vapor as polymer B transfer line; assembly may be removed without removal of spinning beam.
Customer to provide motor/inverter and zone heaters/coolers; integrate pressure and heat controls into balance of control system.
Polymer Prefilters
Quantity 2, one per extruder.
Continuous extended area filters; specifically designed for producing fine denier bicomponent fibers.
Uses cartridge filter elements which may be replaced without stopping process.
Project includes 3 sets of cartridges and all special operating tools.
Electrically heated and custom insulated.
Spinning Beams
Quantity 2 (6 positions each).
Houses final distribution pipes, metering pumps, pump blocks, and spin packs.
Designed for bottom loaded packs, vertical pump drives.
Liquid over vapor Dowtherm heated.
Vent stack assemblies included; customer to handle vented material.
System designed for excellent and uniform heat transfer to spin pumps, pump blocks, and spin packs.
Holds one model BKF rectangular bicomponent staple spin pack in each of twelve spinning positions.
