Proses produksi meltblown

high velocity air blows a molten thermoplastic from a spinninghead onto filament collector to
form a fine fiberous and self bonding web.
Meltblown process consists of the following elements : extruder, polymer filter, gear pump,
heater, spinneret, filament collector, winder

1. Extruder : heated barrel with a rotating screw inside

2. Polymer filter
3. Gear pump
4. Heater hot air : supply the high velocity hot air through the slots on the top and bottom sides of
the spinneret. High velocity air is generated using an air compressor that is passed through a
heater. Typical hot air temperature range from 230 C-360C at velocity of 0.5-0.8 the speed of
sound.
Speed of sound 344m/s
Another source : 300.56 C
Pressure H/A : 1.015 bar
Velocity : 30, 50, 75, 100, 200, 300 m/s
 5. Spinneret : range from 215 C-340C, depending on the polymer used
When producing a die tip, where the distance between orifices is very small, there is less metal
between the orifices and therefore the die tip is very delicate. This can lead to “zippering,”
where the metal between the orifices breaks, at which point the die must be replaced (James,
2000; Wilkie & Haggard, 2007). The molten polymer flows through these orifices to produce
the filament strands (Malkan & Wadsworth, 1993; Zhao, 2002).
6. Filament collector
7. Winder

Process variables : related to machine and can be changed while the equipment is being operated.
Divided into 3 groups ; machine / operational, off-line, and material.
1) Machine variables : hot air temperature, spinninghead temperature, hot distance, collector
speed, polymer throughput, and hot air pressure
a) Polymer throughput and hot air pressure : control the fiber diameter, fiber entanglement,
basis weight
b) Spinneret and hot air temperature : affect the uniformity, fly formation, web appearance
(soft or stiff)
c) Hot distance : affect the thermal bonding among the fibers and basis weight
2) Off-line variables : fixed during a process run and can only be changed when the machine is not
in operation. These variables are air gap, air angle, spinninghead, and spinning hole size.
a) Spinning hole size : affect fiber size
b) Air gap : affect s the degree of fiber breakage by controlling the hot air pressurre.
c) Air angle: control the nature of air flow.
3) Material variables : include polymer type, molecular weight, weight distribution, polymer
viscosity, polymer additives, and polymer pellet size (powdered or granular).

KEY PROCESS FACTORS

The key process parameters in meltblown technology:
1. Polymer melt temperatures
2. Polymer throughput rate
3. Hot air temperature
4. Air flow rate
5. Hot distance
Those process variables play important roles in deciding the morphology and diameter of the fibers
which are the building block of the meltblown nonwoven.

Turbulence??

POLYPROPYLENE
Melting point : 130-171 C
Density 0.895-0.92 g/cm3
Young's modulus : 1300-1800 N/mm2

reference setting machine

Polymer melt initial temperature : 290-335 C
Air initial pressure : 0.1-0.8 Mpa
Accessory air pressure : 0.1-0.4 Mpa
HD : 60-180 cm
A major problem with die tips is the clogging of the small orifices which causes shots and affects the
uniformity of the web.
1988 : Kimberly-Clark patented a die tip known as the slot die. The die has a single slot that is
continuous along the length of the die tip on one side; the other side of the slot has groves to form the
fiber

Influence of Processing Conditions On Melt Blown Web

Structure: Part 1 – DCD
1) Web structure (i.e. a fiber network) begins to develop when fiber
entanglement first occurs (within 1 cm of the die) but network structure is
dynamic and becomes fixed only when fibers contact the collector and their
motion ceases (stop).
2) In this paper, we address the influence of DCD on fiber entanglement, fiber
orientation and pore structure in webs.
3) Evaluate additional processing variables such as primary airflow rate and
water quenching as well as additional web structural features such as basis
weight uniformity and single fiber diameter.
4) Fiber entanglement was dependent on DCD at all primary airflow rates.
When DCD was increased, the percentage of fine fiber bundles decreased
and the percentage of coarse (kasar) fiber bundles increased.
5)
 BFE test is performed to determine the filtration efficiency by comparing the upstream bacterial
control counts to downstream test article counts. A suspension of Staphylococcus aureus was
aerosolized using a nebulizer and delivered to the test article at a constant flow rate and challenge
delivery. The challenge delivery is maintained at 1.7-2.7 x 10pangkat 3 colony forming units (CFU)
with a mean particle size (MPS) at 3+-0.3 micron. The aerosol droplets were drawn through a six-
stage,viable particle, Andersen sampler for collection. This procedure allows a reproducible bacterial
challenge to be delivered to test materials. This test method complies with ASTM F2102-14 and EN
1468:2014, Annex B.
The delta P test determines the breath ability by measuring the differential air pressure on either
side of the test article using a manometer, at a constant flow rate. The delta P test was designed to
comply with MIL-M-36954C, section 4.4.1.2 and complies with EN 14683:2014, Annex C.
All test method acceptance criteria were met. Testing was performed in compliance with US
FDA good manufacturing practice (GMP) regulations 21 CFR Parts 210, 211, and 820.

The strength properties peaked at an MFR 300

MFR higher, strength properties lower
Molecular weight distribution higher, elongation lower
Extruder temperature lower, tenacity and bursting strength higher
Throughput rate higher, bursting strength lower
Air velocity higher, fiber diameter distribution narrower
MFR higher, average fiber diameter lower
MFR higher, web colors lighter