Man-made fibres

Man-made fibres
Marzoli’s technology for man-made and technical fibres
Man-made fibres
Marzoli
Index
Man-made fibres
p. 04
Processing of technical fibres
p. 07
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Man-made fibres
Marzoli’s technology for man-made and technical fibres
Artificial fibres
Synthetic fibres
Man-made fibres can be divided in two main categories: artificial fibres and
synthetic fibres.
Artificial fibres are derived from
natural products (in most cases
cellulose) that are modified by
reactive agents.
Most known artificial fibres from
cellulose:
•
•
•
•
•
•
rayon or viscose;
modal;
lyocell;
cuprammonium;
acetate;
triacetate.
Synthetic fibres are derived from
substances that are not present in
nature, but instead created through
chemical reactions (synthesis)
from petrochemical products. Both
types of fibres can be produced
as a filament or can be cut at
predefined lengths. When the fibre
length is between 30 mm and 60
mm, the fibres are considered short
or commonly called “cotton cut”,
and can be processed in standard
spinning mills.
Most known synthetic fibres from
chemical petrol products:
•
•
•
•
•
•
•
•
•
•
acrylic;
aramid (Kevlar and Nomex);
vinyl chloride;
modacrylic;
polyamide (Nylon);
polyester;
polyethylene;
polypropylene;
polyurethane;
polytetrafluoroethylene (Goretex).
Synthetic fibres have been commonly
used in the textile industry for
several years both for apparel and
for furnishing fabrics and in recent
years they have evolved into new
technical fibres.
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Man-made fibres
Marzoli’s technology for man-made and technical fibres
Technical fibres
In recent years textile products for
technical applications in various
high-tech areas have experienced
great
advancements.
These
materials are composed of natural,
artificial and synthetic fibres and
are capable of offering special
characteristics such as mechanical,
thermal, conduction, durability,
resistance to flame, heat, smoke,
chemicals, etc. Designed and
produced based on particular needs,
they are capable of performance
levels that are not achievable with
traditional fibres. Technical textile
products are formulated by applying
the manufacturer’s knowledge to
the needs of the users. Together
they can identify the desired
characteristics of new products,
the available raw materials and
the most appropriate technologies
to employ. One example in the
architectural field is the production
of fabrics used in structural frame
canopies, or in the apparel and
There are four basic elements that
have to interact and integrate for the
successful development of technical
fabrics:
Innovation is a strategic factor for the success of technical fabrics. Only a
thorough research and development cooperation between the fabric’s user,
the fibre producer and those in charge of the spinning and weaving processes
can produce competitive and cutting-edge results internationally.
• raw materials used to produce
fibres and products with special
mechanical
and
physical
characteristics;
• productive
processes
are
influenced by the machinery
manufacturers and the plant
engineers;
• the production of manufactured
products, where the knowledge,
experience and creativity of the
machinery manufacturers, the
spinners, the weavers and the
finishing experts, all contribute
to perfecting the various
products;
• the users always find and
request new applications and
innovative processes for their
final products.
Generally, technical fibres can be classified in two groups:
furnishing industries, fabrics that
offer fire-proof or anti dust-mites
properties.
In the field of technical textile
products,
natural
fibres
are
becoming irrelevant; synthetic
fibres, instead, have a huge growth
potential, since they can be modified
at the molecular level in order to
develop the desired characteristics.
Technical fibres are designed and
produced with a determined end
use in mind.
• fibres derived from standard fibres through modifications of the productive
process or their polymeric composition with the precise goal of improving
certain technical characteristics. For example, high-tenacity polyester or
flame resistant fibres called FR (Flame Retardant);
• fibres that have been specifically studied and produced for high
performance and industrial use.
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Man-made fibres
Marzoli’s technology for man-made and technical fibres
World end-use consumption of technical texitles by
application area
The growth and wide distribution of technical fabrics
seem unstoppable and is advancing even in countries
that are traditionally more focused on cotton processing.
• interior furnishings: rugs,
carpets, draperies;
• commercial furnishings:
fireproof fabrics;
• geotextiles: soil filtering and
drainage;
• civil engineering and
construction: light and
resistant fabrics of simple
applications;
Agrotech
Buildtech
Packtech
The many uses of technical fabrics in various fields
are such that making investments in technical textile
production and processing plants today is not only a
valid alternative to traditional spinning, but is also an
important step to expanding in areas that are not as
sensitive to heavy crisis that cyclically take over the
global textile market.
Technical fabrics can have endless
applications:
Sporttech
Protech
Clothtech
Geotech
Mobiltech
Hometech
Medtech
Indutech
• medical and healthcare:
hospital furnishing, medical
uniforms, bandages, etc;
• industrial products: conveyor
belts, packaging materials,
food packaging, cleaning, etc;
• filtration: dust filters, gas
separation and purification,
liquids filtration;
• transport: automotive, belts,
airbags, filters, soundproofing;
• apparel: sport and protective,
comfort, safety and accident
prevenction;
−− flame resistant;
−− electromagnetic waves
resistant;
−− antimagnetic;
−− UVA radiation resistant;
−− cut, tear, impact resistant;
−− chemicals, solvents
resistant;
−− thermal;
−− anti-moss, water repellant,
anti dust mites;
−− water proof, breathable.
Thanks to their variety and characteristics technical
fibres are found in all productive and industrial fields
and their spread will continue also in upcoming years.
World end -use consumption of technical
textiles, from 1995 to 2010
26
24
22
20
Million
18
Tons
16
14
12
10
1995
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2000
6
2005
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2010
Man-made fibres
Processing of technical fibres
Production technologies
Marzoli knowledge in
technical fibres
The transformation process from
fibre to yarn to fabric is comparable
to the traditional process used for
cotton fibres: opening, spinning,
weaving, finishing, etc.
Marzoli is the ideal partner for the quality and the
uniqueness of its opening and blending machines,
preparation and spinning.
At the centre of Marzoli’s research, fibre producers,
researchers and clients have actively cooperated to
experiment with the various types of technical fibres
in order to evaluate their spinning capabilities and
the possible end results. Some fibre producers have
installed selected Marzoli machines in their production
departments to experiment directly on their products.
Spinning Process
Although technical and synthetic fibres do not require
cleaning and are of uniform length, the spinning process
is not at all easy or certain; rather, the choice of
equipment and technology, as well as production and
spinning planning, need to be appraised with care. Only
with the best knowledge of the fibres to be employed one
could select the right equipment to obtain the production
and the quality to compete on an international level. The
spinning process must be adaptable to the raw materials
used in order to produce yarns that better showcase the
fibre’s technical characteristics.
MARZOLI
Thanks to partnerships with some of the major producers
of synthetic and technical yarns, Marzoli has acquired
information and experience to design machines capable
of powerfully yet delicately processing these fibres. Our
technologists and our R&D department have actively
cooperated with our customers to find the right solution
for each type of raw material.
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Man-made fibres
Processing of technical fibres
Opening
One of the challenges of working with technical fibres
is the opening of the fibrous mass without scraping,
breaking, weakening the fibre. It is therefore of utmost
importance to choose the correct composition of
opening and blending equipment that will maximize
production and quality. Marzoli’s line of equipment
offers a selection among several types of openers with
different types of variable speed beaters; different types
Superblender
B12 B12
Mixer
B143L
4 cells
4 cells
of carding sectors, feeding rollers and nipping points.
Special finishes and, upon request, stainless steel plates
are available to reduce the wear on parts in contact with
the fibres. The transportation of the fibres with cage
condenser instead of fans (which are used only where
strictly necessary) reduces the formation of neps and
curling in the opening line. High capacity blenders with
pressurized air guarantee homogeneous final products.
Fine opener
B134L B134L
Card
C701
C701
Blending
Carding
When processing synthetic and technical fibres,
different colours of the same fibre or fibres of different
composition are often blended together. Marzoli’s high
production feeders with precision scales can blend up to
five different components and guarantee uniform mixes
keeping blending errors below 1%.
Historically, Italy has been the country of textile and
fashion innovation thanks to the presence of prolific
designers and researchers and it has proven itself again
thanks to technical fibres. In the latest decades, several
large and prestigious Italian groups have contributed to
the unstoppable development of new yarns that take
maximum advantage of the chemical and technical
potential of the new fibres.
Marzoli found itself to be the natural partner of these
technical fibres pioneers and thanks to its intense
dedication and its productive capabilities, has become
the preferred partner for the selection of spinning
equipment.
Starting with the models developed in the ‘80s, Marzoli
cards have adapted to the evolving attributes of technical
fibres. The latest model (offering a carding area of 1.500
mm) has maintained the geometry and diameters of the
carding organs that adapt well to the work required by
this type of fibres. The new geometries, the large carding
surface and numerous combinations of carding sectors
in input and output, have allowed the new Marzoli card
to increase its production rates, while guaranteeing
at the same time efficient opening of the fibrous mass
without fibre damage.
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Man-made fibres
Processing of technical fibres
Spinning
Technical fibres have to be spinned paying special
attention to friction. Excessive friction and increase in
heat can cause irreversible damage to yarn and fabrics.
Roving Frames and Spinning Frames have to keep these
factors into account.
The correct spinning geometry, the antiballon position
and the need of easy removal when required, are very
important features and are characteristic of all models
of Marzoli Spinning Frames. Both Marzoli roving frames
and spinning frames guarantee high flexibility and can
be adapted quickly to production of different types of
fibres. All production parameters can be easily set using
a touch screen. The cylinders can be equipped with
a medium or long cradle; the spinning frame creel is
extremely flexible and can be used for numerous special
yarns applications.
Production Rate
Fibres
Poli Phenil
Sulfide
Para-Aramid
Meta ParaAramid
Polyimides
Polyester FR
Modacrylic
Length mm
51
50
50
53
60
38
Fineness Dtex
2,2
1,7
1,4
2,2
3,3
2,2
Yarn Count Ne
20
30
36
24
24
24
Card C701
Kg/h
60
55
60
58
65
60
Draw frame
mt/min
450
500
500
450
450
500
Roving frame
Rpm
1.000
1.100
1.200
1.100
1.100
1.100
Ring frame
R.p.m.
13.000
14.000
15.000
13.000
13.000
13.200
Machines
production
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Man-made fibres
Processing of technical fibres
In the following tables we show data for
some of the fibres successfully processed
on Marzoli production lines.
Fibre type
Fineness dtex
Length
Fibre type
Fineness dtex
Length
Polyester FR
3.3
60 mm
Polyamide
2,2
53 mm
Yarn Count
Ne 24
Quality
Yarn Count
Ne 24
Quality
U%
Thin 50%
Thick 50%
Neps 200%
RKM (cN/tex)
Elong.%
12.2
38
15
25
23.5
23.00
U%
Thin 50%
Thick 50%
Neps 200%
RKM (cN/tex)
Elong.%
9.0
11
15
14
22.50
22.90
Fibre type
Fineness dtex
Length
Fibre type
Fineness dtex
Length
Modacrylic
1,9
51 mm
PoliPhenilSulfide
2,2
51 mm
Yarn Count
Ne 20
Quality
Yarn Count
Ne 20
Quality
U%
Thin 50%
Thick 50%
Neps 200%
RKM (cN/tex)
Elong.%
9,9
2
4
4
18.00
21,00
U%
Thin 50%
Thick 50%
Neps 200%
RKM (cN/tex)
Elong.%
9,2
0
9
30
26,30
19,70
Fibre type
Fineness dtex
Length
Fibre type
Fineness dtex
Length
Para-Aramid
1,7
50 mm
Meta Para-Aramid
1,4
50 mm
Yarn Count
Ne 30
Quality
Yarn Count
Ne 20
Quality
U%
Thin 50%
Thick 50%
Neps 200%
RKM (cN/tex)
Elong.%
12,0
20
45
85
65
3,5
U%
Thin 50%
Thick 50%
Neps 200%
RKM (cN/tex)
Elong.%
11,5
13
270
690
19,5
18,5
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Man-made fibres
Note
“The text and format of this brochure can be changed
any time with the change in policy matters.”
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Complete
Spinning System
Spinning Section
Short Staple Fibre
- Carded Cotton
- Combed Cotton
- Man-made Fibres and Blends
Draw Frames Combing Section
Carding Section
Opening Section
Galileo
Vi a S . Albe r t o , 10 - 250 3 6 Pa l a z z o l o s / O , B r e s c i a - I taly
Tel. +39 030 7309 1 - Fax +39 030 7309 365 - [email protected]
www.marzoli.it