Compressed air: 900 Nm³/h – for filaments thread-up (not continuous)
Required space – production area: 100 m x 35 m x 6 – 17 m
Required space – warehouse: 2000 m²
Section 1 – Pet Crystallizing
Polymer cleaning group for receiving the polymer in big-bags, consisting of: collection hopper for big bags unloading, screw conveyor, dust exhaust filtering unit equipped with suction fan, cyclone, sleeve filter, metal detector, unloading rotocell, pneumatic conveying unit to transfer the polymer to the storage silos made of suction valve, extraction screw, vacuum unit complete with cyclone, filter and pump, stainless steel pipeline
Crystallizing group for the polymer crystallizing treatment, special configuration for flakes, including: crystallizing hopper, process air drying, vacuum receiver, set of stainless steel pipes for hot air circulation within the units
Drying group for the polymer drying, special configuration for flakes and mainly consisting of: de-humidifying hopper (placed below the crystallizing hopper), process air heater, cyclone filter, dehumidifying dryer for generation of dry air and mainly consisting of set of stainless steel pipes for hot air circulation within the units
Pneumatic conveying system for the transportation of the dried polymer from the de-humidifying hopper to the extruder hopper, consisting of: vacuum unit, vacuum receiver with metal net filter, stainless steel pipeline
2 x extruder hopper to store the dehumidified polymer above the extruders, AISI 304 stainless steel construction with insulation layer and anodised aluminium external covering, material: stainless steel, inspection door, level switch alarm and loading control
Section 2 – Extrusion, Melt Filtration and Spinning, Filaments Quenching, Stretching and Distribution, Web Forming and Fiberglass Reinforcement Application
2 x extruder for pet polymer melting, consisting of an extrusion screw and a barrel heated by electrical resistances assembled in several thermo-controlled zones, special configuration suitable for flakes, screw material: high resistance steel, barrel material: alloy steel with anti-wear coating, electric heating system divided in several zones, temperature probe in each zone, cooling by forced ventilation on the last zone, driving unit with D.C. motor controlled and speed reduction gear with forced lubrication, heat exchanger water/oil type for lubrication system cooling
2 x filtering unit for continuous pet polymer filtering, self-cleaning filter with counter current automatic drain system with partial surfaces, special configuration suitable for virgin pellets or flakes, filter turned on hydraulically and has automatic cleaning cycle based on pressure drop value measured between upstream and downstream melt flow pressure, material: nitrated steel, heating: by electric resistances, piston movement: hydraulic, equipped with hydraulic unit
2 x melt transfer line to transfer the melted polymer from the extruder to the filter changer and from this to the spinning beam, complete with: heated pipelines made of stainless steel and complete with connecting flanges, electric resistances, temperature and pressure probes
2 x spinning beam to uniformly distribute the melted polymer to the spinning pumps, consisting of a steel frame whose high temperature is maintained by a forced circulation of liquid diathermic oil
2 x spinning packs for melt spinning into filaments, one set installed on the spinning beams, one set kept as technological stand-by, each spinning pack complete with: pack body, filtering nets (various layers with different mesh), breaker plate, spinnerets with holes (round section)
2 x filaments quenching system to cool down the filaments by a laminar flow of air with adjustable temperature, air flow generated by a cooling/heating group
2 x filaments drawing and distribution system for filaments drawing through low pressure air ejectors and their distribution on the web forming belt through a movable steel flaps system, including: 2 x set of ejectors each one assembled in one row on a stainless steel compressed air plenum frame, 2 x filaments distribution systems each one equipped with supporting frame, set of fixed and movable flaps ceramic coated, movable flaps driving system by AC motor frequency controlled, mechanical oscillator and driving bar
Web forming conveyor belt made of a woven plastic net that moves on a group of cylinders, one of which is motor-driven, cylinders supported by a steel frame, belt kept under negative pressure by exhausting fans in order to keep the web on the belt, painted sturdy steel frame, 2 x independent high suction sections, 2 x independent low suction sections, set of rollers, two rollers for belt balancing and tensioning, perforated belt, 4 x exhausting fans driven by D.C. motors frequency controlled, automatic belt balancing system with tilting cylinder and pneumatic control, main driving unit by D.C. motor controlled, working width: 4500 mm, speed: 3-25 m/min
Creel for application of reinforcing filaments, double creel for feeding of technical filaments equipped with extractable drawers and with unwinding from the inside, total number of reels in operation: 448, total number of reels in stand-by: 448, creel can be equipped with different types of filament guiding devices for controlled application, also equipped with filament guides, rigid pipes system with ceramic bushes for the transfer and deposit of the filaments
Section 3 – Fabric Bonding, Thermosetting, and Winding
Pre-needling machine, single board needle-punching machine with frame construction made with welded steel, needling from top, working width: 4500 mm, max stroke frequency: 1500/min, speed: 3-25 m/min
Needling machine, machine description similar to the pre-needling machine but without inlet group
Thermosetting unit for thermal stabilization of the non-woven fabric, painted sturdy steel frame insulated with panels filled with mineral wool, perforated drum stainless steel made and equipped with needle rings for keeping the nonwoven and preventing thermal shrinking, process air circulation fan with high efficiency impeller, inlet guiding roll, heating system by diathermic oil, working width: 4400 mm, speed: 3-25 m/min
Outlet calender for the calibration of the nonwoven fabric, painted sturdy steel frame equipped with pneumatic or hydraulic system for the linear pressure, inlet roller with jacketed configuration for heating by diathermic oil
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