Friday, 14 October 2011

Start a Needle punch non-woven fabric production line



(122) Start a Needle punch non-woven fabric production line
Needle punch non-woven fabric production line is one kind of methods for producing non-woven fabrics.
     In the process of producing, instead of using the traditional weaving process of the fabrics, the needle punch bond method uses triangle needles averagely punching in the cotton web to make the fibers directly tangle each other together ; controlling the density, intensity, and function of the fabrics by needle density, needle depth ,needle number, and other physical elements. No water, air, heat and chemicals are needed at all. It is a kind of pure physical and mechanical bonding method, saving energy and non-pollution.
     Finished products maintain 100% yield form ram materials. It is the best green products for environmental protection. And finally it still can be 100% recycled by physical disposal, and can be reused.
     The products made by needle punch bond method are with 3 dimensions’ (3D)effect, with excellent flexibility, and accessible to extension for processing into mold, Furthermore, it is with good ventilation, which the various traditional fabrics can’t be with. The same equipment can be used for various fiber materials, including artificial fiber, synthetic fiber, recycled fiber, inorganic fiber, and metal fiber. The scope of raw materials that can be used is wide and the products that can be produced are almost limitlessly diversified. According to individual industrial requirement, the fabrics can be made into various materials for their special functions. The range of usage is very extensive. It can be used for livelihood products, industrial products, hi-tech aviation. Industrial products, and even national defense industrial products.
     Shoou Shyng (Model 1327) needle punch non-woven fabric production line is one kind of large professional machinery with diversified functions. The raw materials that can be used are the most common, lowest cost, and easiest accessible fibers, such as P.E.T., .P.P., Acrylic, Rayon and Nylons, as long as the fiber number is between 2-3 Din, length between 40-75mm. Either single material or mixed material can be used.
     To meet the market requirement and productive logic, this equipment is set for the products of following five categories:
1.    Felt for garment and doll industries.
2.    Base cloth for artificial leather P.U. or P.V.C.
3.    Filter materials for air, water and bust.
4.    Geotextile for civil engineering.
5.    High absorbent cleaning cloth.
     Considering for a wide variety of products with the machine equipment and production technique in common is the best condition, and the season and the territory for individual product should be also considered, in order that the production line can be adjusted to the best economic capacity, not to cause investment waste but to increase investment margin.
2.2.   Process Description
   (A) Opening & Mixing
      To process different type of fibers from bale stage, blended in the correct proportions by means of openers. The fibers are opened and dispersed for the preparation of carding process.
   (B) Feeding
      The fibers are blown from the opening machine which supply a predetermined Quantity to Cards by electric auto scale controlled system.
   (C) Carding
      The fibers fed into the carding machine are snared by the wire of rotating cylinder and fibers are aligned in an essential parallel direction. A web or net is formed on card and removed form the card by doffer to the cross lapper.
   (D) Crosslapping
      Fiber webs layered to increase the fabric’s cross directional strength, thickness. weight , width and improve uniformity.
   (E) Web Feeding
      Layered web can be adjusted to meet the standards of any specifications and delivered to needle punching by means of Web Feeder . The Web Feeder is to avoid the layered web to be deforming and tractility.
   (F) Preneedle Punching
      The layered web are fed through a series of needle punching machines, the Preneedle Punching is to interlace the various layers each other with lower needle density. It is a preliminary 3D interleaving to entangle the fibers.
   (G) First Double Side Finish Needle Punching
      The layered web are delivered by means of conveyor and rollers to first double side finish needle punching loom. The operation will make the web becomes the middle high density nonwoven fabric.
   (H) Second Double Side Finish Needle Punching
      The applications of geotextile and filtration need high tensile and high entanglement nonwoven fabric. Special fibers have developed that permit them to be converted into soft, fine finish fabric to be high density structure.
   (I) Calender
      After the fabric has been sufficiently interlaced by two times double side needle punching, the fabric can be fed through calenders to further compress.
(J) Slitting, Winding and Edge cutting
      Nonwoven roll goods are converted in a variety ways, such as slitting to the widths required for end product converting , edge cutting for end product packing, and rewinding to prepare rolls of appropriate for product converting.

3.  Plant Description
3.1.   Production Capacity
          A needle punch nonwoven fabric plant equipped with machinery and equipment in this proposal, operating 16 houra (2 shifts) a day, 25 days a month, should be able to produce the needle punched fabric as beiow.
Working With:3.6 Metera
End Product. With: 3.6 Meters
End Product Range of Weight: 150gsM~800gsM
Production Line Speed: 1.5~7.5 Meters/minute
Raw material spec:2d~15d
Maximum Capacity:
P.P 15d-250kg/hour
Polyester 6d-200Kg/hour
Rayon 3d-100Kg/hour
3.2.  Manpower Required
Job Classification
Person/Shlft
General manager
Staff
Skilled Machining Operator
Maintenance & Inspection
1
2
4
2
Total:
9
3.3.  Machinery & Equipment
Item
Set
Bale Opening Machine
Fiber Opening Machine
Fiber Hopper
Carding Machine
Crosslapping Machine
Preneedle Punching Loom
First Double Side Needle Punching Loom
Calender
Slitting & Winding Machine
Edge Cutting Machine
2
2
1
1
1
1
1
1
1
1
3.4.   Utilities
Electric Power Machine capacity 300KW , 3 Phases AC
380/220V , 60/50 HZ
Air 5 Kg/cmx 200 IB/min
3.5.   Plant Site Planning
     The needle punching non-woven production free industry , no need Water , steam and oil. The plant should be located in a district or an area where the production of various textile with a significant scope of future expansion.
3.6.   Area of Land and Building
Item
Area Required (M2)
Plant
Raw Material Warehouse
Finished Product Warehouse
Production Line
3,600
600
600
1800
The total area required for needle punching non-woven plant is shown as below.
Model-SPL-1327


4.   Supplier Information
Shoou Shyng Machinerty Co., Ltd
556-1, Chung Cheng Rd., Hsnchuang, Taipei
Tel:             886-2-29012245          Fax: 886-2-29041366
URL: http://www.shoou-shyng.com
E-mail: shoou@ms29.hinet.net

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