FET Pilot Melt Spinning System for Continuous Filament Yarn

MAde by FET : Fibre Extrusion Technology Limited UK
Machine used in composite trial showroom in 2020 for the preparation of fibres for automotive composite fabrics developments
1. Melt spinning of continuous filament yarns multifilament
2. High speed draw winding for multifilament
3. Multi polymer capability
4. Polymer drying and preparation
5. Ancillary support equipment, water chilling, tools for calibration, spin pack cleaning and preparation
6. Remote diagnostics and on-line technical support (by separate contract with the manufacturer)
7. Polymer loading and additive dos


1. One Melt Spinning Extrusion Module
Extrusion Module mono and option for bi-component capability, air quenching of multifilaments.
Materials: PP, PET and PA plus other thermoplastic materials
Mono-Component Yes
Bi-Component (conjugate): Cost Option
Process temperature Up to 400°C
Melt Capacity of extruder Up to 20.0 kg/hr polypropylene
Melt Capacity of extruder Up to 30.0 kg/hr polyester

2. One FET-101 Multifilament Draw Winding Module
High speed melt spinning, draw winding extrusion line for the production of Continuous Multifilament
Yarns:
Yarn Type: Fully Drawn Yarns (FDY)
No of Thread Lines: 1
Yarn Types, Mono-Component: Yes
Number of Draw Zones 3
Yarn Types, Bi-Component: No
Yarn Cross Section: Round, others are available
Denier Per Filament Range: 1 to 20
Line Speed: to 2,500 m/m (max godet and take-up speed)

Typical FET Series 100 melt spinning system, spin draw wind, for production of
continuous filament yarns from thermoplastic polymers, complete with Auto-Revolving
Take-Up Winder

1. One FET-100 Melt Spinning Extrusion Module – Mono-Component Capability
1.1 ONE Extruder
FET 40/30 Extruder, high base fabricated steel construction. Specification as follows:
Screw Dimensions ø40mm - Ratio 30:1 LD
Screw Material EN40B Nitride hardened
Feed Jacket Water Cooling
Screw Speed 0 - 80 rpm
Barrel Material EN41A
Barrel Heating Zones 4
Type of Heater Ceramic type, (5 x 2kW) 10 kW total
Thermocouple Type Chrome/Alumel (type 'K', braided)
Temperature range Up to 400°C
Gear Reducer Type Helical Gear
Motor Drive Capacity 11 kW AC
Motor Control Variable Frequency AC Inverter
Temperature Control Microprocessor /PID/Solid State
Nitrogen Feed Port Available

1.2 ONE Polymer Distribution Manifold
Polymer distribution manifold is mounted above the spinning head.

1.3 ONE Spinning Head Mono-Component Capability
FET melt spinning extrusion head, electrical resistance heated. Capable of producing mono-component
continuous multifilament. External insulation by ceramic fibre with stainless steel protective outer covers.
Specification as follows:
Material High chrome P20 alloy steel
Manifold Heating Cartridge type (4 x 1kW ) 4kW Total
Spin Pack Heating Ceramic Type 1.5kW
Thermocouple Type Chrome/Alumel (type 'K', braided)
Temperature Control PID control system
Spin pack aperture Diameter 110mm
Temperature Range to 400°C
Melt Temperature Included

1.4 ONE Metering Pump & Drive System
To ensure constant output from the extruder without changing melt-flow characteristics between different
batches of polymer, two precision metering pumps are mounted directly onto the spinning head.
Specification as follows:
Material Tool steel
Capacity 1 x 15 cc/rev
Motor 1 x 1.1kW AC with 1024 PPR Encoder
Speed reducer Worm reduction gear, connection via universal Joint
Motor Control Variable Frequency AC Inverters
Heating Ceramic type 0.6kW
Thermocouple Type Chrome/Alumel (type 'K', braided)
Temperature Control PID control system

1.5 THREE Mono-Component Spinning Packs for Multifilament
The machine will be supplied with 3 sets of mono-component spin packs.

3 Spin Packs Spin Pack Diameter Format 110mm Multifilament

1.6 SIX Mono-Component Spinnerets for Multifilament
The machine will be supplied with the following Spinnerets:

6 No. of Spinnerets 6 110mm TBA Spinneret Diameter Hole ø & No. of Holes

1.7 ONE Control System (Computerised)
State of the art computerised control system for monitoring and controlling all parameters. (Temperature,
Pressure, Speed and Recipes) All parameters displayed on a Universal Operator Interface with LCD
Display. To include:
On machine Siemens 15” HMI for operator control.

Siemens software overview:
Recipe system
Acquisition and archiving of all process data.
Correlation analysis with all other data.
Powerful and robust log-term Historical archiving.
Highly flexible reports.
Combined display of data, alarms and events in the Trendviewer to trace cause and effect.
All data exportable either via CSV or OPCUA.

Capable of controlling:
1. One Extrusion Module
2. One Drawing and Winding Module for Multifilament

1.8 Consumables For Start-Up
Machine is supplied with a minimum supply of start-up consumables, additional quantities are available on
request at an extra charge. Specification as follows:
Spin Pack Filters 100 filter elements 40,80,100 & 200 mesh.
Spin Pack Sealing Gaskets 100 aluminium gaskets (Spinneret)
Spin Pack Sealing Washer 100 aluminium gaskets (spin pack and die head)

1.9 ONE Air Quench Cabinet
Filaments are cooled by means of controlled air directed across the filament path. System incorporates
variable air velocity control and temperature regulation. Specification as follows:
Air Flow Width 400mm
Blow Air Height 2000mm
Depth 250mm
Air Velocity 0.2 – 0.8 m/sec
Air Regulation Inverter Drive
Air Supply Centrifugal Blower 2.2kW

1.10 ONE Spin Finish Application System
Metered ceramic guides mounted at the base of the Air Quench Chamber. Ceramic guides are adjustable
in and out.
Applicator 1 position Ceramic nozzles (Total 2 nozzles)
Metering Positive displacement by metering pump
Output 2 x 0.03cc/rev
Motor 1 x 0.12kW AC with 1024 PPR Encoder
Speed reducers Helical reduction gear, via flexible coupling
Speed 0 to 33 rpm
Supply Tank Capacity 4 litre
Adjustment Multi-directional: Up & down, in & out plus rotating

1.11 ONE Drawing Station (3 draw zones)
High efficiency draw station to permit controlled yarn orientation and relaxation. Machine is equipped with
1 draw station, designed to process 1 yarn. Specification as follows:
Duo Induction heated Draw Rolls
Duo Induction heated Draw Rolls
Duo Induction heated Draw Rolls
Duo Induction heated Draw Rolls
Microprocessor Electronic Temperature Control
Heated Godet Roller Specification.
Diameter ø190mm
Cylindrical Length 210mm
Working Length 160mm
Max. Working Temperature 210°C
Heating Full roll induction heater
Temperature Transmission Induction
Sensor Rotating PT 100 transmitter
No of Zones Single
Coating Plasma LC-4
Finish 0.8 – 1.0 Ra
Motor Type Reluctance Motor Type ARS 90
Speed 200 – 2,500 m/m

1.12 ONE Air Entanglement Device
Each thread passes through an air interlacing jet. This process provides assistance with
final package formation, and also further downstream processing of the yarn. Frequency of
entanglement nodes is determined by yarn tension and air pressure used.
Mounted in line after final godet pair and before Winder
Make Heberlein, Model Polyjet

1.13 ONE Hand Aspirator Gun
Hand held high speed Aspirator unit for thread-up of machine. Specification as follows:
Yarn Speed Max 3000 mtrs/min
Denier range Max 1000 denier total
Air Pressure 6 to 16 (kg/cm2), required min 6 bar at the gun
Air Consumption 225Nm3/hr at 6 bar


1.14 ONE Automatic Precision Cross Winder
Single machine with 1 winding position type Twinstar Sahm 380XE HS. Specification as follows:
Basic Material PP Multifilament
Machine Speed 100 – 2,500m/m
Max. Package Diameter 320mm
No of Yarns 1
Nominal Traverse Stroke 250mm
Package Form Cylindrical with Straight Ends
Titre Range 50 -2,500dtex
Tube Inner Diameter 94mm
Tube Outer Diameter 106mm
Tube Length 290mm
Type of Tube Cylindrical
Winding Material Multifilament
Yarn Tension Adjustment Pneumatically adjustable dancer arm
Yarn Tension Range 50 – 800 cN
Note Not possible to obtain multiple limiting values

1.15 ONE Machine Cabinet
The system is housed in a self contained and free standing stainless steel cabinet mounted on adjustable
wheels and lock down feet.

1.16 ONE Mezzanine
For mounting extruder module above air quench unit.

Optional & Ancillary Support Equipment

2. ONE Polymer Drying System
THROUGHPUT - 5KG PER HOUR
MATERIAL – PA or PET
DRYING TEMPERATURE – 140 – 160 DEGREES C
DWELL TIME - 4 TO 6 HOURS
TO DRY GRANULATE PET AT A THROUGHPUT OF APPROXIMATELY 5KG PER HOUR AT A
DRYING TEMPERATURE OF 160 DEGREES C WITH A DWELL TIME OF 4 TO 6 HOURS.
POLYMER TRANSFER FROM DRYER TO EXTRUDER IN HERMETICALLY SEALED HOPPER
SYSTEM.

3. ONE Water Cooler Unit
Packaged Water Chiller Unit to provide cooling water to heater exchanger for the air quench system,
including pump, maximum ambient 25°C. Specification as follows:
Thermal Duty 7.35Kw
Fluid type Water
Cooling fluid flowrate/pressure 0.75m³/hr @ 2-3bar

4. SET Tools & Calibration equipment
Infra red temperature sensor
Yarn Tension meter
Tachometer
Airflow meter
Stroboscope

5. ONE Die Cleaning System and Spin Pack Preparation
Die cleaning system for cleaning spinnerets, die head, comprising:

5.1 Cleaning Oven
High temperature muffle furnace
Operating temp 1100°C max
Capacity 23 litres
Internal dimensions 235 x 245 x 400mm
Installed power 7.5KW

5.2 Ultrasonic bath
Ultrawave Ultrasonic Cleaning system
Capacity 19.5 litres
Internal Dimensions 502 x 297 x 150mm

5.3 Inspection
Inspection microscope
20 x magnification

5.4 Spin Pack Pre-heat Oven

6. SET Documentation
The following documentation will be included
CE Marking
Preventative maintenance plan
User manual (English version)
Technical drawings of equipment

7. ONE Remote Access Via Modem Connection
Remote access to computerised control via Modem connection to allow diagnostic work.
Remote modem/broadband access for diagnostics
Provision of on line support for 12 months
Customer to provide ASDL line

8. ONE Polymer Loading Unit and Volumetric Dosing Units

8.1 One Hopper Loader System with machine hopper and polymer day bin
To convey virgin granulate from a 120 litre mobile day bin to extruder at a throughput of 20kg/hr
over a vertical conveying distance of 4 to 5 metres
Hopper Loader Metro HBS 400/1 3 phase conveying station for the automatic loading of extruder hopper
with free flowing material
Extruder Material Hopper with sight glass and connection for hopper loader

8.2. One Motan Colortronic Minicolor V-G1 Volumetric Dosing and Blending System
To dose 2 additives at a throughput of 1 and 5% MINICOLOR V-G1 (CAN)