TT1201: Raw materials and

Fibre Science II
Fiber manufacturing process : Man made fiber spinning
Man Made Fiber Spinning
 Three types of man made fibers (MMF)
MMF are produced in three types –
1. Filament: Filament fibres are spun from spinnerets with 350
holes or less is determined by the size of the yarn to be made
Monofilament: This filament is made only of a single
filament.
Multifilament: These filaments are made of more than one
filament.
2. Staple:Staple fibre is of limited and relatively short length
3. Filament tow. An assemble of twist free fibre.
 Properties required for Fibre forming polymer:

• Molecular weight should be high.

• Crystallinity – high not suitable.
• Resistance to different chemical.
• Orientation – Physical and chemical symmetry.
• Straight chain structure.
• Glass Transition Temperature (Tg) – Should be near to Room Temp.
• Crystalline Melting Point (Tm) - 200o – 300o c is suitable.
• Polymer should be soluble in some solvent from which it can be spun.
• Hygroscopic nature – Should be hydrophobic
Properties required for Fibre forming polymer
1. Molecular Weight:
The molecular weight of a fiber-forming polymer should be high. High molecular weight
polymers offer increased strength, durability, and resistance to wear and tear. They also tend
to have better mechanical properties, such as tensile strength and toughness, which are vital in
textile applications.

2. Crystallinity:
While some degree of crystallinity is necessary for structural integrity, high crystallinity may
not be suitable for fiber formation. Highly crystalline polymers tend to be stiff and less flexible.
Therefore, textile polymers usually have a lower degree of crystallinity to ensure flexibility and
softness in the final fabric.

3. Resistance to Chemicals:
A fiber-forming polymer must resist various chemicals, including those found in detergents and
environmental exposure. Resistance to chemicals is crucial to ensure the durability and
longevity of textile products.
Properties required for Fibre forming polymer
4. Orientation:
The polymer chains should have both physical and chemical symmetry, promoting
alignment and orientation during the spinning process. This alignment enhances the
mechanical properties of the fibers, such as strength and elongation.

5. Straight Chain Structure:

Polymers with straight-chain structures are preferred because they offer a more
orderly arrangement of polymer chains. This results in improved fiber strength and
reduced entanglement during processing.

6. Glass Transition Temperature (Tg):

The glass transition temperature (Tg) of the polymer should be close to room
temperature. This ensures that the fiber remains flexible and amorphous at typical
ambient conditions, making it comfortable to wear and easy to process.
Properties required for Fibre forming polymer
7. Crystalline Melting Point (Tm):
An ideal polymer for textile applications should have a crystalline melting point (Tm) in
the range of 200°C to 300°C. This range allows for thermal stability during normal use
and processing without risk of melting or deformation.

8. Solubility in Solvents:
The polymer should be soluble in specific solvents, which allows it to be dissolved and
spun into fibers. This solubility is essential for the manufacturing process, as it enables
the creation of a solution or melt that can be extruded into fibers.

9. Hygroscopic Nature:
Fiber-forming polymers should be hydrophobic, meaning they repel water. This
property is important in textiles as it helps to keep moisture away from the body,
ensuring comfort and maintaining the insulating properties of the fabric.
Properties required for Fibre forming polymer
These properties collectively influence the performance and
characteristics of the fibers, making them suitable for various textile
applications.
Understanding and optimizing these properties is crucial for textile
engineers to develop high-quality and functional textile materials.
• Spinneret: A nozzle or plate provided with fire holes or slits through a fibre
forming solution or melt is extruded in fibre manufacturing is called
spinneret. This is the most important part of a MMF producing m/c. The
number of holes, sizes and shapes vary with the filament desired.
• Shape of holes:
Spinneret
 Features of Spinneret:
Spinneret length: 10-25 mm
Spinneret diameter: 30-200 mm
Spinneret thickness: 3.0 mm
Hole dia: 0.1.-0.8 mm
Problems:
-Breaking (On account of high pressure and temp)
Clogging (The holes can be blocked for solid particles mix with polymer solution).
Remedies:
-For breaking problem: the spinneret is to be changed.
-For clogging: the spinneret should be cleaned after some days.
 Number of holes in spinneret:
1. For monofilament:1-3
2. For multifilament: 100-1000
3. Filament tow:up to 50,000

Flow chart of MMF production:

1. Manufacture of the fibre forming polymer.
2. Spinning ( extrusion through spinneret)
3. Stretching/Drawing ( improving strength and crystallinity)
4. Texturing/Crimping ( developing natural fibre properties)
5. Intermingling/Interlacing( applied instead of twisting)
6. Heat setting( made dimensionally stable)
7. Cutting: According to requirements.
 Manufacturing of fiber forming polymer
• All man made fibres are composed of long chain molecules known as polymer
which are formed by chemical processing.
• Common groups in polymers –
• Amide or Peptide groups ( -CO-NH-)
• Benzene ring
• Ether linkage( -C-O-C-)
• Ester linkage(-C-O-O-)
• Hydroxyl group (-OH)
• Nitrile group (-C-N-)
 Spining
• The conversion of polymer into fibre is called spinning. The fibre forming
substance is made temporarily fluid, extruded through spinneret and then
returned to solid state (by solidification) in fibre form.
• Three types of spinning process:
• Melt spinning (Synthetic).

• Wet spinning.

• Dry spinning.
 Man Made Fiber Spinning
Technology
SPINNING of polymers

There are typically three types of spinning for polymers: Melt, Dry and Wet.
▪ Melt spinning (Fig. 1) is used for polymers that can be melted easily.
▪ Dry spinning (Fig. 2) involves dissolving the polymer into a solution that
can be evaporated.
▪ Wet spinning (Fig. 3) is used when the solvent cannot be evaporated and
must be removed by chemical means.
 Man Made Fiber Spinning Technology
Melt spinning
In melt spinning the fibre-forming material is melted and extruded through spinnerets, and the jets harden
into solid filaments as they cool on emerging from the spinneret. Nylon is a melt-spun fibre.

Dry spinning
In dry spinning the fibre-forming substance is dissolved in a solvent before the solution is extruded. As the
jets of solution emerge from the spinneret, a stream of hot air causes the solvent to evaporate from the
spinning solution, leaving solid filaments. Acetate is dry spun by extruding acetone solutions of cellulose
acetate into hot air.

Wet spinning
In wet spinning the solution of fibre-forming material is extruded into a coagulating bath that causes the jets
to harden as a result of chemical or physical change.
Viscose, for example, is wet spun. The solution of cellulose xanthate is extruded into an aqueous solution of
acids and salts, in which the cellulose is regenerated to form solid filaments.
Man Made Fiber Spinning Technology
 02. Spinning: Melt spinning:
• The process of spinning by which fibre or filament is produced from melted
polymer chips by extruding through spinneret continuous filament produced
here.
• Number of filament depends on number of holes in spinneret.
• It is the most critical operation in the production of nylon polyester, and
polyolefin, poly propylene fibres as number of fibre properties such as
uniformity, crystallinity, and orientation are imparted to the yarn during
processing.
 02. Spinning: Melt spinning:
•.Flow Chart
Feed

Melting

Metered extrusion

Cooling &
solidification by
cold air.

Moisture
conditioning

Lubrication

Yarn driving

Packaging
 02. Spinning: Melt spinning:
Advantage:
• Can be used for both staple and continuous filament.
• Direct and simple process.
• No environment pollution.
• No solvent required.
• Non toxicity and no risk of explosion.
• High production speed (2500 – 3000 ft/min)
• Low investment cost.
• Disadvantage:
• Required more proper maintenance of the m/c.
• Heat of input is high.
 02. Spinning: Melt spinning:

Typical melt spinning:

Polymer Melting point
Nylon – 6, 6 264oC
Nylon – 6 220oC
PET 264oC
Polypropylene 167oC
Poly ethylene 125oC
 02. Spinning: Dry spinning:
• In dry spgn, the fibre forming polymer dissolved in a volatile solvent is
introduced into a heated drying chamber where the solvent is evaporated
and solid fibre is obtained through spinneret.
• This process is used for Acetate and some polyacrylonitrile fibre.
 02. Spinning: Dry spinning:
• Dry spinning solvent:
Fibre Solvent
I) Cellulose -Acetone + (2-6) % water
II) Triacetate -Methylene chloride (40%)
+ Methanol (10%)
III) Poly acrylonitrile -Di-methyl formamide or
Dimethyl acetamide.
IV) Spandex - DMF, DMAC.
V) Modacrylic - Acetone.
 02. Spinning: Dry spinning:
•. Feed

Metered extrusion

Solidification by solvent

Evaporation

Lubrication

Yarn driving

Packaging
Dry spinning Process
Dry spinning Process
 02. Spinning: Dry spinning:
• Advantage:
• Suitable for producing fine denier fibres.
• No need of wash of fibre.
• Disadvantage:
• Investment cost is high.
• Toxic and risk of explosion.
• Heat input is very high.
• Can not be used for staple fibre production.
• Properties of solvent:
• Solvent should not be volatile.
• It should be organic.
• It should have low boiling point.
• It should be comparatively cheap.
• It should be thermally stabilized.
• It should be non toxic.
 02. Spinning: Wet spinning:
• In wet spinning a suitable solvent is used to prepare fibre forming solution and
another coagulant is used in coagulating bath.
• Solution is extruded through spinneret and in contact of coagulant cellulose is
regenerated.
• Wet spgn solvent & coagulant:
Fibre Solvent Coagulant
Viscose Alkaline water Dill H2SO4 + Na2SO4 +ZnSO4
PVA Water Aqueous NaOH
PAN DMF/DMC + Aq DMF/DMC + 40% ZnCl2
• 60% ZnCl2
02. Spinning: Wet spinning:
 02. Spinning: Wet spinning:
• Advantage:
• Suitable for staple fibre.
• Both organic and inorganic solvent can be used.
• Low temp reqd.
• Higher production due to continue spgn.
• Softener process.
• Investment cost is low.
• Disadvantage:
• Slow spgn speed.
• Washing and bleaching of fibres are needed.
• Toxic.
 02. Spinning: Difference
Parameter Melt spgn Dry spgn Wet spgn
1. Investment cost Low High Low
2. Hazard Non toxic Toxic Toxic
3. Heat of spgn High Very high Low
4. Spinneret hole 2 – many 300 – 900 20000 – 75000
thousands
5. Spgn speed 2500 – 3000 2500 – 3000 150 – 300 ft/min
ft/min ft/min
6. Productivity High Low High
7. Application Filament or Filament Filament or
staple staple
8. Solvent Not required Only volatile Both organic and
organic solvent inorganic solvent
can be use.
Comparative features of melt, dry and wet
spinning

Features Melt Dry Wet

Investment Cost Low High Low

Toxic
Hazard Non-toxic (Risk of
Toxic
explosion)

Heat of Spinning High High Low

2 to many
Spinneret Hole 300-900 20,000-75,000
thousand

Spinning Speed 2500-3000 2500-3000 150-300 ft/min

ft/min ft/min
 Advantage of man-made fiber technology:

•Production does not depend on climate & location.

•Quality & quantity can be controlled during production.

•Length & thickness can be controlled as per requirement.

•Staple length can be controlled as per requirement.

•Smoothness and high luster.

•Fiber processing is easier.

•High productivity and low cost.

 Disadvantage of man-made fiber
technology:

1. Fabrics made of MMF are difficult to stitch.

2. Low air permeability.
3. Uncomfortable.
4. Unhygienic.
5. Hydrophobic.