Company founded 1975 US-based machinery business experienced in worldwide sales.

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Spandex Filament Yarn Production Plant, 4500 t/a, Dry Spinning Technology

Description

  1. Overview
    1. One existing industrial full plant (process machinery and equipment, utilities, services) for the polymerisation / dry technology spinning / solvent recovery to produce around 4,500 t/a spandex filament yarn starting from MDI and polyol.
    2. The plant has a nominal capacity of approximately 4,500 tons/annum (upgrade to 5,000 is achievable) and is based on the dry spinning process.
    3. The plant has been producing high quality spandex yarns by dry technology since 1996 up to 2008, using modern equipment, advanced engineering solutions, high level of automation and accurate recipes to optimize product quality, production costs and to enhance HSE full respect.
    4. Spandex is used for elastane fibres, respectively polyurethane fibres with high elasticity and recovery.
    5. Elastane yarns are incorporated into textile applications where their high elastic extension and high recovery forces are advantageous; they are never used alone in fabrics, but in combination with other yarns, either as bare yarn or as covered elastic yarn.
    6. Applications include woven fabrics (narrow fabrics, jeans, leisure and sports wear, city fashions, fashionable outerwear, shoes), warp knitted fabrics (tricot knits, raschel fabrics), knitted fabrics (pantyhose, underwear, leisurewear, outerwear, sportswear), and other fabrics (diapers, sanitary articles, medical articles).
    7. Over 80% of elastane is produced by dry spinning.
  2. Plant Layout
    1. Raw materials: polyol (PTHF) and pure MDI (methylene diphenyl di-isocyanate).
    2. End product: spandex filament yarn.
    3. End product output: around 4,500 t/a resp. 12.8 t/d on the average at 8,400 operating hours per year.
    4. Fineness range: 17 – 420 dtex, 44 dtex on the average.
    5. Production program (example): 2% - 17 dtex, 12% - 22 dtex, 12% - 33 dtex, 61% - 44 dtex, 8% - 78 dtex, 5% - 156 dtex.
    6. Polymerisation plant: 2 semi-continuous production lines.
    7. Dry spinning plant: 16 spinning lines, each with 8 to 10 cells, i.e. in total 144 cells.
    8. Number of yarn ends: 24 - 32 per cell (17, 22, 44 dtex), 4,288 in total.
    9. Number of winders: 2 per cell, for 12-16 ends each.
    10. Package weights: 0.3-0.4 kg (17, 22 dtex), 0.5-0.7 kg (44 dtex), 0.5 kg (78 dtex plied), 0.5 – 1.0 kg (156, 235 dtex, plied) on standard tubes with 57-114 mm length.
  3. Capacities
    1. Polymerisation: total installed name plate capacity is 2,400 kg/h dope (with 35% b.w. concentration).
    2. Dry spinning: example of a production plan for 16 spinning lines based on expected capacities and production days/annum.
    3. Lines A-B-C-D (4 x 8 cells): 1 line at 17/1 dtex, capacity 291 kg/24h, production period 350 d/a, capacity 101.85 t/a; 3 lines at 22/1 dtex, capacity 350 kg/24h each, total 1,050 kg/24h, production period 350 d/a, capacity 367.5 t/a.
    4. Lines E-F-G-H (4 x 8 cells): 1 line at 22/1 dtex, capacity 485 kg/24h, production period 350 d/a, capacity 169.75 t/a; 2 lines at 33/2 dtex, capacity 800 kg/24h each, total 1,600 kg/24h, production period 350 d/a, capacity 560 t/a; 1 line at 156/12 dtex, capacity 580 kg/24h, production period 350 d/a, capacity 203 t/a.
    5. Lines I-L-M-N (4 x 10 cells): 2 lines at 44/3 dtex, capacity 1,280 kg/24h each, total 2,560 kg/24h, production period 350 d/a, capacity 896 t/a; 2 lines at 44/3 dtex, capacity 1,050 kg/24h each, total 2,100 kg/24h, production period 350 d/a, capacity 735 t/a.
    6. Lines O-P-Q-R (4 x 10 cells): 3 lines at 44/3 dtex, capacity 1,050 kg/24h each, total 3,150 kg/24h, production period 350 d/a, capacity 1,102.5 t/a; 1 line at 78/6 dtex, capacity 1,050 kg/24h, production period 350 d/a, capacity 367.5 t/a.
  4. Condition
    1. The plant has been producing high quality spandex yarns by dry technology since 1996 up to 2008.
    2. It uses modern equipment, advanced engineering solutions, high level of automation and accurate recipes.
  5. Included
    1. Polymerisation plant with 2 semi-continuous production lines.
    2. Dry spinning plant with 16 spinning lines, each with 8 to 10 cells (144 cells total).
    3. Solvent recovery system.
    4. Utilities and services.
    1. Details to be further developed.