Integrated Process Control and Air Handling Optimization for Spunbond Non-Woven Lines
Problem Definition
Industry Challenges
- 01 High specific energy consumption (kWh/kg) due to inefficient process air attenuation and heating systems
- 02 maintaining consistent fiber diameter and web uniformity at high production speeds (>600 m/min)
- 03 Managing polymer rheology variations affecting filament formation
Specific Pain Points
- Significant Cross-Direction (CD) basis weight profile variation exceeding ±3%
- Frequent filament breakage leading to 'drips' and subsequent line stoppages
- Inability to dynamically adjust quench air velocity based on polymer throughput changes
Current State Analysis
Performance Impact
Engineering Verification
This solution has been validated by Atlamech Engineering based on the following standards:
View DetailsTechnical Scope
- Retrofit of Quench Air system with VFD-controlled high-efficiency centrifugal fans
- Implementation of closed-loop GSM control using inline Beta-gauge feedback to extruder pumps
- Upgrade of winder tension control system with load cell feedback and AC Vector drives
Compliance Standards
Implementation Strategy
Key Deliverables
Consultation Notes
Process Air Dynamics
The stability of the quench air is critical for filament cooling and attenuation. Design must ensure laminar flow within the quench chamber to prevent filament fluttering. Rectifiers and honeycombs must be inspected for blockage or deformation.
Tension Control & Winding
For high-speed non-woven lines, surface winding with gap control is preferred to prevent roll telescoping. Tension zones must be isolated using S-wrap bridles. The control loop should utilize a calculated diameter reference augmented by load cell feedback.
Safety Considerations
Given the high inertia of calender rolls and winders, Safe Stop 1 (SS1) is required. Standard VFD STO (Safe Torque Off) is insufficient for high-inertia loads without controlled braking ramps. Mechanical braking redundancy must be verified.
Polymer Filtration
Ensure continuous screen changers are integrated into the pressure control loop to prevent pressure spikes during screen indexing.
Infrastructure Taxonomy
Knowledge Areas
Engineering Relation Summary
Technical Components
VFD-controlled centrifugal fans, Inline Beta-gauge feedback, Safe Stop 1 (SS1) function
Engineering Constraints
Control Cycle Time < 10ms
Core Optimization Logic
Calculated diameter reference logic
Implementation Evidence Summary
Project Brief
Spunbond Non-Woven Line Process Control and Quench Air Optimization
Technical Knowledge Cluster
Spunbond Non-Woven Process Control and Aerodynamics
Technical analysis of integrated automation and air handling systems in spunbond manufacturing, targeting improvements in filament uniformity, tensile strength, and energy efficiency through closed-loop control.
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