Solutions to Fuzz Generation in Polyester Monofilament Production
(I) Equipment Maintenance and Improvement
Regular Maintenance and Part Replacement: Establish a comprehensive equipment maintenance system to conduct regular inspection and maintenance on key components such as thread guides and rollers. Once component wear is detected, replace the parts in a timely manner. When selecting components, prioritize materials with high wear resistance and surface finish, such as ceramic thread guides. With their smooth surface and high hardness, ceramic thread guides can effectively reduce wear on filaments and lower the probability of fuzz generation.
Optimization of Tension Control System: Perform regular calibration and debugging on the tension control system to ensure uniform and stable tension on filaments throughout the production process. Advanced tension sensors and automatic control systems can be adopted to monitor and adjust tension in real time. Fine adjustments are made automatically according to the operating status of filaments, ensuring that filament tension remains within the optimal range at all times.
(II) Process Parameter Optimization
Precise Control of Spinning Temperature: Install high-precision temperature sensors to monitor the spinning temperature in real time, and accurately adjust the temperature through an automatic control system. Determine the appropriate spinning temperature range based on different raw material characteristics and production requirements, and strictly control the temperature fluctuation within an extremely narrow range, generally within ±1℃, to ensure the stability of the melt and the quality of filaments.
Reasonable Matching of Winding Speed: Determine the optimal matching relationship between spinning speed and winding speed for polyester monofilaments of different types and specifications through experiments and production practice. During the production process, adjust the winding speed in a timely manner according to actual conditions to ensure that the winding speed is compatible with the spinning speed. This avoids excessive stretching or over-cooling of filaments caused by speed mismatch.
(III) Raw Material Quality Control
Strict Slicing Screening: Strengthen the management of polyester chip suppliers and establish a strict raw material inspection system. Conduct comprehensive testing on each batch of incoming chips, including indicators such as intrinsic viscosity, carboxyl end group content, and impurity content. Only chips that meet the quality standards can be put into production, ensuring raw material quality from the source and reducing fuzz generation caused by chip quality issues.
Selection of High-Quality Oil Agents: Cooperate with professional oil agent suppliers and select oil agent products with excellent performance. When choosing oil agents, focus on inspecting indicators such as their lubricating performance, antistatic performance, and stability. At the same time, reasonably adjust the oil agent formula and oiling process according to different production processes and filament requirements, ensuring that the oil agent can fully exert its effect. This reduces friction between filaments and equipment components, decreases static accumulation, and effectively inhibits fuzz generation.
