In melt-blown fabric production, the cleanliness of spinnerets and nozzle heads directly impacts fiber quality and spinning stability. Traditional cleaning methods suffer from operational complexity, nozzle damage, and environmental pollution. This paper introduces an innovative non-contact cleaning solution based on German water particle technology, utilizing a specialized spinneret cleaning machine independently developed by Shanghai Tense Electromechanical Equipment Co., Ltd. The proposed approach provides the industry with a new technical reference for efficient and eco-friendly cleaning solutions.
I. Industry status and cleaning difficulties
The spinneret mold is a critical component of spinning machines, designed to transform viscous polymer melts or solutions into fine streams with specific cross-sectional profiles through micro-pores. These streams solidify via a cooling medium or bath to form filaments. During spinning, mechanical impurities, carbon fibers, and gels may clog the spinneret holes. Partial blockages cause solution overflow on the spinneret plate's outer surface, resulting in uneven filament fineness and issues like thin or hairy filaments. Complete blockages significantly increase breakage rates, severely compromising fiber quality. Therefore, regular cleaning of spinneret plates is essential to maintain optimal performance.
The melt-blown fabric spinneret plate has a very small aperture (generally less than 0.2 mm), which is easily blocked by polypropylene residue, carbide and oil during use. Traditional cleaning methods such as chemical dissolution, flame burning or mechanical scraping can remove some impurities, but there are the following problems:
1. The wall of the hole is easy to be corroded or deformed;
2. The cleaning process is accompanied by chemical gas or waste liquid discharge;
3. Low cleaning efficiency and high labor cost.
Traditional cleaning methods:
1. High temperature calcination + ultrasonic cleaning
Cleaning process and characteristics:
1. Calcine at 400~500 degrees for 6~8 hours to carbonize the micropore blocking material;
2. Use the cavitation effect of ultrasonic cleaning and special cleaning agent to clean for about 1~2 hours to decompose the residues in the micropores;
Disadvantages: The overall cleaning process takes a long time, the vacuum calcination furnace has waste gas, and the service life of the spinneret plate is affected by repeated calcination of the spinneret plate assembly
2. Dry ice cleaning method:
Cleaning process and characteristics:
1. Use heating tube or hot air gun to repeatedly heat the mold body. According to the size and model of the mold, the heating time is about 30~200 minutes or more to soften the blockage in the micropore;
2. The dry ice cleaning system utilizes thermodynamic principles to detach contaminants through differential contraction rates. When-78°C dry ice particles contact contaminants, they undergo brittle fracture and explosive disintegration, causing the debris to shrink and detach. Simultaneously, the ice particles vaporize instantly and expand 800 times their original size, generating a stripping force that effectively removes contaminants from surfaces.
Disadvantages: The repeated expansion and contraction of the spinneret mold will damage the mold itself
With the continuous improvement of environmental protection requirements and product accuracy, manufacturing enterprises urgently need a new type of safe, fast and non-destructive cleaning method.
2. Innovative methods: German water particle cleaning technology
The spunbond plate cleaning machine developed by Shanghai Tense Electromechanical Equipment Co., Ltd. utilizes advanced German water particle cleaning technology. This innovative system converts tap water into fine particles through the main unit. Under high-speed rotation and pressurized conditions, these water particles deliver intense energy impacts to both the workpiece surface and micro-pores.
Crush and peel off the clogged polymer residue;
Thoroughly remove the solidified impurities in the spinneret channel;
At the same time, the metal matrix is protected from any damage.
The whole process only uses ordinary tap water as the medium, no need to heat, no need to chemical agents, no pollution emissions, no harm to the mold body, is a real sense of pure physical cleaning technology.
III. Process flow and time efficiency
1. Put the spinneret into the special cleaning chamber;
2. Start the device, and the water particles rotate at high speed to impact the micropores;
3. The polymer is crushed and carried out with the water;
4. After cleaning, it can be dried and tested directly.
Taking a 1600 mm melt-blown spinneret as an example, the entire cleaning process can be completed in about 30 minutes, greatly improving the efficiency of production and maintenance.
IV. Cleaning effect and comparison results
The permeability of the spinneret hole is significantly improved, and the uniformity of the spinneret is restored as new;
No chemical corrosion marks on the surface, no need for subsequent grinding treatment;
The cleaning cycle is shortened by more than 60%, and the production downtime is significantly reduced;
Zero emission, zero addition, to achieve real green cleaning.
V. Suggestions for high quality cleaning and maintenance
1. Regular maintenance cleaning of the die and spinneret;
2. Use pure tap water and keep the filtration system unblocked;
3. Record each cleaning parameter and establish equipment maintenance files;
4. Select appropriate pressure and cleaning time according to the degree of pollution;
5. Cooperate with ultrasonic or hot air drying system to further improve the efficiency of cleaning and drying.
With the breakthrough application of water particle cleaning technology, Shanghai Tianshi Electromechanical Equipment Co., Ltd. has provided the melt-blown fabric industry with truly efficient, environmentally friendly, and non-destructive cleaning solutions. The equipment not only significantly extends the service life of spinnerets but also helps enterprises achieve energy conservation, emission reduction, and green production, facilitating the upgrade of China's manufacturing industry towards high quality and sustainability.
Post time: Nov-03-2025