PET / PLA Eco-Friendly & High-Temperature Spunbond Line Manufacturer - BOSTONE
BOSTONE offers specialized PET/PLA Spunbond Line turnkey solutions. We specialize in stable extrusion technology for high-melting point polyester and biodegradable polylactic acid, helping you achieve efficient production of differentiated products for geotechnical, filtration, medical, and sustainable applications.
PET/PLA Spunbond Line
| Model | Effective Width | Weight | Max. Speed | Output |
|---|---|---|---|---|
| SSS | 1600mm | 8-80gsm | 400 m/min | 4000 TPA |
| 2400mm | 6000 TPA | |||
| 3200mm | 8000 TPA | |||
| 4800mm | 12000 TPA |
| Raw Material | Effective Width | Weight | Max. Speed | Output |
|---|---|---|---|---|
| PET/PLA | 1600-5200mm | 12-150gsm | 200m/min | 5000 TPA |
Technical Challenges and BOSTONE's Refined Solutions
The spunbond processing of high-performance polymers such as PET (polyethylene terephthalate) and PLA (polylactic acid) presents significantly greater technical complexity compared with conventional PP (polypropylene). PET is characterized by a high melting point, rapid crystallization, and strong thermal stability, making it ideal for demanding industrial applications that require high strength and heat resistance. PLA, as a bio-based and biodegradable material, holds great potential in eco-friendly and hygiene-focused markets, yet its narrow processing window and susceptibility to hydrolysis introduce additional challenges during production.
Challenges and Countermeasures for PET Spunbond Line
| Technical Challenge | Detailed Problem Description | BOSTON'S Refined Solution |
|---|---|---|
| High Melting Point & Thermal Degradation Control | PET melting point is about 260°C. Long-term high-temperature retention or local overheating can cause molecular chain breakage (thermal degradation), which affects fiber strength and color, and causes spinneret blockage. | Dedicated High-Torque Extruder & Heating System: Adopts a customized high-torque screw, minimizing shear force; integrates multiple precise heating control modules to ensure melt temperature fluctuation is $\leq \pm 1^\circ\text{C}$; optimized flow channels minimize melt retention time in the barrel. |
| High Strength Drawing & Fiber Uniformity | PET fibers require higher draw ratios during drawing to impart strength and modulus. Unstable drawing easily leads to fiber breakage and uneven thickness. | High-Efficiency Positive Pressure Drafting System: Utilizes a special positive pressure/tube drafting process to provide high and stable air flow, achieving high draw ratios of $1:3500$ or even higher. Coupled with advanced deposition control, this ensures uniform netting of ultra-fine fibers. |
| High Crystallinity & Dimensional Stability | PET production requires crystallinity to achieve heat resistance and structural stability. Improper cooling and hot rolling can lead to high shrinkage. | Precision Temperature Control Calendering & Heat Setting Unit: Employs three/four-nip high-precision hot roll calenders. Customized calendering patterns and secondary heat setting (Annealing) units ensure precise control of fiber crystallization, guaranteeing low thermal shrinkage in high-temperature applications of the non-woven fabric. |
Challenges and Countermeasures for PLA Spunbond Line
| Technical Challenge | Detailed Problem Description | BOSTONE'S Refined Solution |
|---|---|---|
| Hydrolysis Sensitivity of PLA Melt | PLA is highly hygroscopic. Water molecules react with the polymer at high temperatures, leading to a rapid decrease in molecular weight and significantly reduced fiber strength. | Integrated Ultra-Efficient Pre-heating & Dehumidifying Drying System: Strictly controls the moisture content of PLA granules to below 50 ppm (far below the industry standard) at the front-end mixer and dehumidifying dryer, fundamentally eliminating water-induced hydrolysis risks. |
| High Melt Viscosity & Spinning Stability | PLA melt has high viscosity and poor fluidity, making it difficult to produce ultra-fine fibers and easily causing melt accumulation or blockage at the spinneret exit. | High-Precision Metering Pump & Low-Resistance Components: Utilizes a high-precision melt metering pump to ensure stable melt output; optimizes melt conveyance pipelines and distributor design to reduce flow resistance, ensuring stable and uniform melt flow through the spinneret. |
| Product Softness & Brittleness | PLA fibers are inherently harder and stiffer than PP, which may result in a finished product lacking the required softness and hand-feel, making it unsuitable for certain high-end hygiene applications. | Dedicated Spinning & Hot Rolling Process: Effectively lowers the crystallinity and improves the hand-feel and softness of the PLA non-woven fabric by adjusting the spinning temperature and cooling rate, and by using low-pressure, special-pattern hot rolling processes without causing thermal degradation. |
Technical Advantages and Equipment Highlights
Stable Continuous Extrusion for High-Melting Point Polymers
This line is equipped with a dedicated precision extrusion system engineered for high-melting point Polyester (PET) and high-viscosity Polylactic Acid (PLA). We utilize specially designed heating elements and barrels to precisely control the temperature uniformity of the PET melt (at ≥ 260℃), with fluctuations kept within ±1℃. This technology prevents thermal degradation during high-speed extrusion, securing the fiber strength and color stability of PET products and enabling long-term, fault-free continuous production.
Ultra-Fine Denier Fiber Technology for Superior Hand Feel
Our spinning components feature an optimized design, giving us industry-leading fine denier fiber spinning capabilities. Through high-precision spinnerets and accurate cooling control, we can stably produce PET/PLA fibers with a monofilament linear density below 1.0 dtex. The advantage of ultra-fine denier is a significant increase in the nonwoven fabric's specific surface area, simultaneously improving the product's softness, uniformity, and coverage. This makes it suitable for demanding medical and hygiene applications, providing a superior user experience.
High-Speed, High-Efficiency Positive Pressure / Tube Drawing Process
Addressing the need for higher drawing forces in PET/PLA fibers at high speeds, we utilize high-efficiency positive pressure airflow or tube drawing technology. This system delivers an extremely stable air current, achieving a very high draw ratio that imparts exceptional MD and CD strength to the fibers. By eliminating turbulence found in conventional drawing, this technique ensures stable fiber transport and uniform laydown, allowing the entire line to support production speeds easily reaching 300M / Min, significantly boosting capacity.
Functional Customization Capability for Differentiated Applications
The structure of our production line is highly adaptable for functional masterbatch integration and compounding, enabling easy product differentiation. Whether it's adding flame retardant masterbatch to meet safety standards for construction and automotive industries, blending in anti-UV agents to enhance durability for agricultural and geotechnical fabrics, or fulfilling the requirements for accelerated degradation in PLA products, this line ensures stable processing. This gives your final product unique functional advantages in filtration, heat resistance, and sustainability over generic PP products.
Supporting facilities and system configuration for PET/PLA spunbond nonwoven production lines
Raw Material Handling and Crystallization System
| No. | Equipment Name | Function and Composition | Specifics for PET/PLA |
|---|---|---|---|
| 1 | Slice Drying & Crystallization System | Used for pre-crystallization and deep drying of polyester chips (PET) to cope with its high melting point and viscosity. Usually composed of a drying hopper, heating system, and dehumidification system. | 【PET Exclusive】Ensures extremely low moisture content (usually < 50 ppm) of the chips before extrusion, effectively preventing hydrolysis and degradation during extrusion and guaranteeing fiber strength. |
| 2 | PLA Ultra-Efficient Dehumidifying Drying System | Specifically designed for hydrolysis-sensitive PLA. Employs a molecular sieve dehumidifying dryer or similar ultra-efficient system to strictly control the moisture content of PLA granules to below < 50 ppm. | 【PLA Exclusive】This is key to stable PLA spinning, preventing a sharp drop in melt molecular weight and ensuring the mechanical performance of the fibers. |
| 3 | Color Masterbatch Drying / Automatic Metering System | Ensures the color masterbatch is fully dried before adding. Composed of a drying device and a high-precision Loss-in-Weight metering device. | 【High Precision】Uses Loss-in-Weight metering instead of manual addition, ensuring extremely high precision and continuity of masterbatch addition, suitable for performance differentiation needs of PET/PLA products (such as anti-UV, flame retardant). |
Melt Extrusion and Purification System
| No. | Equipment Name | Function and Composition | Specifics for PET/PLA |
|---|---|---|---|
| 4 | Single Screw Extruder | The slices are extruded and melted. It consists of a transmission device, a high-torque gearbox, a special screw, ceramic heaters, an automatic temperature control/cooling and alarm system. The main drive uses AC variable frequency control. | [High Durability/High Precision] A wear-resistant, high-torque screw is used for high melting point PET. A Pt100 platinum resistor heating rod and temperature control module are used to ensure the melt temperature fluctuation is small (≤ $1^\circ\text{C}$). |
| 5 | Vertical Dual-Cylinder Melt Filter | Filters impurities and gelled matter from the melt. The dual-chamber switching design allows for expanded production capacity. Metal-to-metal sealing is adopted to ensure reliable high-pressure sealing. | [High Pressure/High Cleanliness] Suitable for high melting point and high viscosity melts like PET. Four independent valve sets are controlled, allowing for non-stop switching to ensure high cleanliness during continuous production. |
| 6 | High Precision Metering Pump and Drive (Gear Pump) | Accurately meters the volume of the melt conveyed to the spinneret assembly, ensuring consistent melt flow from each spinneret hole. | [High Precision] Optimized for the characteristic of high melt viscosity of PET/PLA, ensuring extremely high stability and uniformity of the melt flow under high temperature and high pressure conditions. |
Spinning, Drawing, and Web Forming System
| No. | Equipment Name | Function and Composition | Specifics for PET/PLA |
|---|---|---|---|
| 7 | CL Latest Spinning Box | The melt forms nascent fibers through the spinneret inside the box. | [Special Insulation] Adopts a multi-zone precise heating and insulation design to ensure uniform temperature inside the box, meeting the needs for PET fiber fineness and high-speed spinning. |
| 8 | Single Suction Device (Double-Row Parallel Multi-Tube Type) | Cools and stabilizes the nascent fibers. | [High-Efficiency Cooling] Adopts an efficient and uniform cooling structure design, rapidly cooling and crystallizing the PET melt, providing the necessary conditions for subsequent high-speed drawing. |
| 9 | New Side Blowing Device (Aluminum Frame/Stainless Steel Sealing Plate) | Further stabilizes and cools the fibers. | [Airflow Uniformity] The new design focuses on a highly uniform side blowing airflow, which is key to achieving uniformity in fine-denier fibers, while also ensuring thermal insulation. |
| 10 | High-Efficiency Positive Pressure Tube Drawing Device (Referencing Japanese Morimoto Technology) | Adopts a new drawing air duct structure, utilizing high-speed airflow to highly draw the fibers, imparting high strength. | [High Draw Ratio] This is key to the PET production line, achieving high positive pressure and highly stable airflow, ensuring the fibers do not break at high speeds (up to 300 M/Min) and achieve high strength. |
| 11 | New Web Former | Assists in laying fibers to form a web. Equipped with suction and airflow equalization systems. | [High-Speed Stability] Optimized the web curtain suction and airflow equalization structure, ensuring the fiber web can still be laid uniformly and smoothly onto the web curtain even under high-speed drawing, suitable for high-speed PET production. |
Consolidation and Winding System
| No. | Equipment Name | Function and Composition | Specifics for PET/PLA |
|---|---|---|---|
| 12 | Two-Roll High Precision Hot Rolling Calender | Upper roll engraved and lower roll polished, for thermal bonding and shaping of the fiber web. | [High Precision Temp. Control & Pressure] Requires precise control of the PET/PLA crystallization process, demanding extremely high uniformity of roll temperature and accuracy of pressure regulation, to ensure product strength, hand feel, and low shrinkage. |
| 13 | Automatic Winder | Slits and winds the final product. Effective working width 3500mm. | [High Tension Control] Equipped with a high-precision tension automatic control system, suitable for the stiffness of PET fibers, ensuring winding flatness and edge quality. |
Have Anything To Ask Us?
Please fill in your email in the form and we’ll get back to assist you soon!