Polypropylene Fabric, also known as PP fabric, is a modern and synthetic fabric used for upholstery, manufacturing, and industrial applications. This fabric is soft, lightweight, easy to clean because this fabric has no active dye composition. It is also durable. And it can be cleaned with bleach, even with dark colours. In this article, we will discuss How to produced PP fabric.
PP – Polypropylene Fabric Manufacturing Process
Polypropylene fabric is manufactured by polymerizing propylene. After then, the polypropylene is rolled out using a device known as a spin rate. The spin rate determines the entire thread size and length. After the threads have dried, they are cut into yarn using a mix of different colours and sizes. The cloth is then knitted with polypropylene yarns.
Here is the step-by-step guide for producing Polypropylene fabric.
a. Extraction of Propylene:
Polypro hydrocarbons, like other plastics, are produced from ingredients derived from fuels such as petroleum oils. In the extraction process, monomer propylene is extracted as gas from crude oil. Then this monomer is utilized to produce polymer polypropylene.
b. Creation of Polypropylene:
After that, this monomer is then subjected to a process to create the polymer. Finally, solid plastic material is formed when a large number of propylene monomers are strung together.
The molten polymer is absorbed by the spinning gear pumps, which travel through the spinning pack to consolidate the product and avoid variations caused by the screw extruder. Next, the polymer is supplied into an extruder in pellets or granules, where it melted and is pushed to the melted spin pack through a positive displacement.
A multifilament spinneret receives molten polymer through a spin pack that comprises filters and channels. The molten material is applied to the die surface by the distributor. According to the denier required, the diameter of the die ranges from 0.5 to 1.5 mm.
Newly extruded molten filaments exiting the spinneret are cooled, generally by cool air, and hardened without causing damage to the filaments. The cooling area can be as simple as an area where quenching air is blasted over the filaments. On the other hand, it might be a complex chamber with a well-regulated chilling environment.
In the final step, they cut these thin fibres into the desired shape and sewn or glued them to create garments or diapers. For forming polypropylene into non-woven products, a variety of different manufacturing methods are used.
This stage of PP fabric production involves finishing the fabric to improve the fabric antistatic and reduce friction. In addition, it is heated to enhance its physical and mechanical properties, and crimping is done to improve black.
Thermosetting is a process that uses hot air or steam to loosen the fibres by releasing the fabrics internal pressures. The fabric’s fibres are set with reduced-increased opacity after thermosetting.
After that, the fibres are cut to a length of 20 to 120 mm. Depending on whether the system is made of cotton or wool.
Polypropylene Fabric Characteristics
- Durable, lightweight, and soft fabric, the density of its fiber is the lowest than other synthetic fibers.
- Polypropylene nonwoven fabric is good chemically resistant. Most acids and alkalis are immune to fibers.
- PP fiber has a lower heat conductivity than other fibers. It can be employed in thermal wear applications.
- It is not a moisture-absorbent material. It indicates the fibers wet and dry characteristics are the same. Low moisture recapture is not viewed as a drawback because it aids in the rapid transfer of moisture, which is necessary for applications such as dry diapers.
Read More: PP Fabric: Nonwoven Polypropylene Fabric