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Neumag, Staple Fiber Extrusion and Drawing System, 30 Million Lbs/Yr Capacity, 2-Step Process

Description

  1. Overview
    1. Inventory number: E-5596
    2. Neumag staple fiber extrusion and drawing system – short gap, 2-step process.
    3. Estimated plant capacity: 30 million pounds per year, based on 2000 lbs/hr per extruder at 92% extruder and spinning utilization and 95% conversion in the spinning area.
    4. System utilized polyester bottle flake as raw material.
  2. Extrusion System
    1. Two 6-inch 32:1 Sterling APV extruders, each with 500 hp motor, Reliance drives, and temperature control cabinets.
    2. Three additive systems per extruder for TiO2, optical brighteners, and black masterbatch.
    3. Spin manifolds and spin blocks included; each extruder feeds eight spinning positions.
    4. Spin packs, spinnerets, spin pumps, controls and drives, spin blocks, and Dowtherm heating system included.
    5. Spin packs are 20.5 in long x 5.75 in wide x 5.75 in high; spinnerets are 1501, 2000, and 2302 holes.
    6. Plant previously ran 12 and 15 denier polyester carpet yarn fibers and geotextile and nonwoven materials.
    7. Spin packs are bottom loaded with an electric hoist.
    8. Quench cabinets: 16 positions.
    9. Product transfer lines are electrically heated; manifold and spin beam are Dowtherm heated; Dowtherm vaporizer is electrically heated.
    10. Spinning takeoff system includes two finish applicator rolls, slub catcher, lost end/breakout detector tied into a data collection system computer, and an air heated 2-inch diameter grooved turning roll device.
    11. Eight spare extruder screws (2 used, 6 new) and one spare barrel in inventory.
    12. Pack handling, cleaning, and inspection equipment included, along with burnout ovens, pack preheaters, and ancillary equipment.
    13. Extruders and pack handling equipment located on a second-story mezzanine; mezzanine and related steel structure included if desired.
  3. Neumag Staple Draw Line
    1. Tow creel with square polyethylene tow bins.
    2. Neumag draw line with 1100 mm rolls, right-hand line construction.
    3. Three seven-roll godet stands.
    4. One Neumag dip bath, 10 ft in length, with multi-spray high-volume/finish cascade system, external high-volume pump, and shell and tube heat exchanger supplying the first dip bath and first draw stand.
    5. Two Neumag 10 ft length steam chests between the three seven-roll draw stands.
    6. Three-ply tow stacking device between the third draw stand and the tension stand assembly.
    7. One Neumag crimper, 250 mm wide, with steam injection ports and associated supply piping and gauges.
    8. One Proctor Schwartz gas heated conveyor dryer, 33 ft length.
    9. One Lummus tow cutter.
    10. One undrawn tow canning system for loading tow in boxes.
    11. No bale press available.
  4. Raw Material Handling and Blending
    1. One six-station Conair-Franklin box dumping and blending system.
    2. 80,000 lb capacity storage silo (outside).
    3. Flake conveying system, screw auger type, with auger feed to 30,000 lb capacity feed silo (inside) with auger feed to extruders.
    4. Drying hopper included; desiccant dryer system not available.
  5. Equipment Inventory and Year
    1. Extruder 1 – Sterling APV, 500 hp motor, 32:1 L/D, Reliance drives (1990).
    2. Extruder 2 – Sterling APV, 500 hp motor (1990).
    3. Screen changer 1 and 2 (1990).
    4. Neumag spin beams (4) with pumps, motor, drives – 16 positions (1990).
    5. Take up wall – 16 positions with take up waste blowers (1990).
    6. Dowtherm boiler, 1300 bars (1990).
    7. Additive feed system (3) for TiO2, optical brightener, color (1990).
    8. Spin pack oven – Gruenberg.
    9. Burn off oven – PCP, 270,000 BTU, gas fired (2001).
    10. Screw conveyors (3) (1990).
    11. Tow guide stand – Neumag (1990).
    12. Immersion bath – Neumag (1990).
    13. Draw stand 1 – 7 roll, 150 hp GE motor (1990).
    14. Steam chest – Neumag, 25 hp Marathon (1990).
    15. Draw stand 2 – 7 roll, 300 hp DC (1990).
    16. Steam chest – 25 hp Marathon (1990).
    17. Draw stand 3 – 500 hp motor DC (1990).
    18. Draw frame – Wellman (1994).
    19. Dancer rolls – Neumag (1990).
    20. Steam box – Neumag (1990).
    21. Crimper – 75 hp Reliance motor DC (1994).
    22. Feeding belt – Neumag (1990).
    23. Dryer – Proctor & Schwartz (1990).
    24. Tension stand – DM&E (1997).
    25. Cutter – Lummus DM&E (1997).
    26. Boilers – 30 hp and 50 hp, Hurst (1990).
    27. 80 ton chiller – Ruhack (1990).
    28. 100 ton chiller – Carrier (1998).
    29. Conair loader – box dumper, 6 stations (1990).
    30. Tow bins – polyethylene, approximately 120.
    31. Raw material drying hopper – Conair (1990).
    32. Tow canning unit for boxed tow.
    33. Silo – 80,000 lb capacity, outside (1990).
    34. Feed silo – 30,000 lb capacity, inside.
    35. Spare parts – 6 extruder screws, 1 barrel, Sterling APV mfg. (2001).
    36. One tow packing/boxing system for boxing undrawn/drawn tow.