Spunbonding process

The spunbonding process is a nonwoven manufacturing technique, whereby polymers are directly converted into endless filaments and stochastically deposited to form a nonwoven material. 

The REICOFIL® spunbonding process is successfully employed to produce Polypropylene, polyethylene, polyester and polyamide nonwovens. 

The REICOFIL® spunbonding process has continually been developed since 1986. It is based on the wish to make the process as simple to control as possible and to be energy efficient in comparison to similar processes. 
 

Process components

	Preparation of raw material
	Dosing unit for primary polymer, pigments and additives
	Extruder for melting and conveying the raw materials
	Melt filter
	Spin pump to ensure a constant throughput to the spin unit
	Sheet distributor with spinneret
	Filament cooling
	Filament extension
	Discharge unit (diffuser)
	Web forming machine for discharge and conveyance of the filaments
	Nonwoven bonding, preferable calendering
	Winding

Process description:

Out of the silo the polymer is vacuumfed to dosing station on top of the extruder. Inside the extruder it becomes melted and homogenised. Passing a filter system and a spin punp, the melt is distributed by a coathanger die, feeding the spinneret which forms a curtain of filaments. The filaments are cooled by means of a stream of air in a blowing area, drawn by aerodynamic forces and then transported to the downstream discharge channel. Here the filaments are swirled around and then deposited on the wire mesh belt as a random nonwoven material. This is transferred to the heat bonding calender which by heat and pressure sets the physical properties as tensiles and elongation of the final product. After calendering the material is cooled by a water-cooled pair of rolls and then wound up.

The Reifenhäuser REICOFIL® spunbonding technology convinces by simple handling and low energy consumption (1 - 1.2 kWh/kg) for melting and conveying the raw materials.

Applications 

	Hygiene
	Industrial applications
	Dust collectors
	Filtration

Physical properties

	High air permeability
	Thermo-bonded - no chemicals
	Excellent bi-directional and wear properties
	Soft and comfortable
	Grammage between 10 - 100 g/m² (150 g/m²) if possible
	Possible additional nonwoven features:
	- Printing  - Laminating - Electrostatic charging - improved hydrophilic properties through application of     tensides
	By using additives or pigment pastes
	- Dying in every imaginable shade - fire-retardant properties - antistatic properties - increased UV and gamma ray protection