Polypropylene Staple Fibre
Polypropylene (PP) is the first stereo regular polymer to have achieved industrial importance. PP Fibres were first introduced to the textile industry in the early 1970’s and soon became an important addition in the rapidly growing market of synthetic Fibres.
Polypropylene is a thermoplastic manufactured from Propylene gas in presence of a catalyst such as Titanium-Chloride. Besides, PP is a by-product of oil refining processes. Most Polypropylene used is highly crystalline and geometrically regular, opposite to amorphous thermoplastics, such as Polystyrene, PVC and Polyamide, with randomly placed radicals. On the other hand, PP has higher working temperatures and tensile strength than Polyethylene. PP is recyclable and has the number “5” as its resin identification code –
Polypropylene Staple Fibres are produced by converting staple Fibre grade Polypropylene resin/granules to Fibre/filament by traditional melt spinning process. Globally, all manufacturers often use special equipment such as Polypropylene staple Fibre spinning + extrusion machines and other specialized machinery depending on the end application.
PPSF has wide ranging applications in view of its being a light weight Fibre with high insulation properties and good resistance to abrasion. PPSF is finding new and varied uses over older and more traditional synthetic Fibres. Among all synthetic Fibres in the world, the share of PPSF has increased substantially and the growth trajectory continues.
Due to its high chemical resistance and low molecular weight, Polypropylene staple Fibre is an ideal material for a wide range of finished product applications such as manufacture of High-Efficiency Particulate Air (HEPA) Filtration Fabric, Battery Separators Fabrics, Manufacture of High-Strength Paper, Floor Coverings, Carpet Backings, Conventional Ring Spun Yarn Filter Fabrics, Non-Woven Filter Fabrics, UV Stabilised Geotextiles, Refractory & Construction and Hygiene (Hydrophilic) based products such as female sanitary products, wipes & medically approved masks.
Highlights
Manufacturing Process
Polypropylene (staple Fibre) grade resin/granules can be converted to Staple Fibres by traditional melt spinning process. Globally, manufacturers use special equipment such as Polypropylene Staple Fibre spinning+extrusion machines and other specialized machinery depending on the end application.
The Standard Production Process can be explained in the following steps:
| 1.Metering | PP resin polymer is metered through spinnerets having holes (depending on the Titer/Performance required) to form filaments. |
| 2.Spinning | The spinning pack consists of three parts i.e. filters, distributor which distributes the molten polymer over to die surface and the die. |
| 3.Quenching | The extruded Fibres are solidified by air/water quenching i.e. the cool air is distributed without damaging the filaments |
| 4.Finishing | Spin Finish is added to improve the antistatic properties and reduce abrasion. |
| 5.Hot Stretching | The Fibres are stretched several times in a chemically heated bath for enhancement of the Fibres physio-mechanical properties. |
| 6.Crimping | The Fibres are then crimped to be made suitable for various spinning systems. |
| 7. Thermosetting | This step is a treatment in hot air or steam that removes the internal stresses and relaxes Fibres. The resultant Fibres are heat-set with increased Titer. |
| 8.Cutting | The Fibres are finally cut into 6 to 120 MM cut lengths, depending on the systems they are required. |
Major Applications
Polypropylene Staple Fibres are chemical resistant and have a low molecular weight and are available in fine, standard and coarse denier ranges in various cut lengths offering high and superior high tenacity and is produced for tailor made applications.
Polypropylene Staple Fibre is an ideal material for a wide range of finished product applications such as manufacture of High-Efficiency Particulate Air (HEPA) Filtration Fabric, Battery Separators Fabrics, Manufacture of High-Strength Paper, Floor Coverings, Carpet Backings, Conventional Ring Spun Yarn Filter Fabrics, Non-Woven Filter Fabrics, UV Stabilised Geotextiles, Refractory & Construction and Hygiene (Hydrophilic) based products such as female sanitary products, wipes & medically approved masks, etc.
Zenith’s range of PPSF can be used to for producing any of the above applications and the same is enumerated in detail herein-below: