Who we are
Heda Group, Our Zhejiang-based factory has a subsidiary in Shanghai. We have been producing synthetic polyester staple fiber since 2015. With the factory’s two production lines, we can produce up to 200tonnes daily. The steady output enables us to service the domestic and international market. Countries we have exported to include Russia, UAE, India, Brazil, Colombia, and Spain.
What We Offer
We produce virgin and recycled Staple fiber for use in the home textile industry. two brands are the solid (microfiber) and Hollow Conjugated siliconized and non-siliconized fibers.
The factory produces high-quality staple fiber for commercial markets. The range of customers includes distributors, wholesalers, importers and textile manufacturers. Others are end-users like wadding factories, dealers in pillow manufacturing, fluffy toys, and cushion.
How We Manufacture the Polyester Staple Fiber
Our goal is not only to produce fiber. But, also offer valuable knowledge to the client on the product they are purchasing. Here is a walk through of the process of making staple fiber. The Production of Staple fiber happens into two phases:
- Spinning line (phase)
- Finishing line (phase)
As the names suggest, spinning implies the creation of fiber. Finishing is altering the final look to make it appealing.
The Spinning line processes
The spinning stage employs a five-fold process as shown below;
Both virgin and recycled PSF go through the same process except at the initial step. For the virgin PSF, the first step is combining PTA and MEG to produce the Polymer. The raw material for making Recycled PSF is already in PET form so, it doesn’t go through polymerization. Rather the PET bottle flakes undergo cleaning and melting to turn them molten.
The molten PET goes through a screw extruder where filtration removes impurities. It also allows time and pressure for the mixture to reach the right spinning consistency. The machine achieves this by passing the molten PET through a spin beam. The spin beam distributes the flow before going to the spinneret.
The main stage of the making PSF is spinning. As the molten PET comes out from the micro holes of the spinneret, it changes into a monofilament fiber. Quenching is more like a high-pressure air sprayer. The air from the quenching machine cools and solidifies the molten PET into filament. The pressure, speed, and uniformity of the air sprays affect the quality of the staple fiber. Hence, the manufacturer adjusts these as necessary in this stage.
From quenching, the filaments pass through a winder section. In the winder oiling and damping the fiber takes place. This improves its quality and ability to absorb chemicals during the after treatments. Next, the godet roller directs the filaments to a take-up unit system. Here two types of roller systems; drawing off and sunflower rollers feed the tow into towing cans. These rollers rotate at low speed for easy operation when pulling up the fiber.
A synchronized unit of cans aids in the collection of tow coming from the winder. The cans fill with the tow to a set weight that signals the system to move the full can out and replace it with an empty one. The process repeats the collection in preparation for the finishing phase.
The Finishing Line processes
The second part of the production is going through the spin finish. Finishing involves adding touch-ups and treatment to improve performance. Likewise, there are five steps;
At the Creel
Separation of the tow into sheets before transferring to the draw bath occurs here. The creel divides it into sheets of three. To split the sheets in uniform sizes they them dip in a bath. At this point, they are ready for stretching. The creel stand also helps in drawing the fibers without entangling them.
Stretching is a two-part process that uses a hot draw bath. From the creel, the tow goes to a stretcher containing a hot chemical bath of about 60-80 degrees Celsius. It is the first drawing. The second drawing occurs in a steam box chest between the second and third stretcher. These chemicals help to stretch the fibers before crimping.
It is a method of achieving irregular shrinkage on fiber. Three things happen to the tow first; cooling, oiling, and stacking together. Two or three sheets are stack into one sheet to ensure good quality crimping. It then goes to the crimper after pre-heating by passing through a tension roller. The crimper squeezes the fiber to shrink it.
This process adds properties that are useful for staple fiber applications. For example, it adds bulk and wool-like appearance to fabrics.
Cutting and Drying
The tow moves up to a tension stand machine for cutting to create Polyester staple fiber. Passing fiber over the tension stand helps achieve even length when cutting.
They dry the staple fiber by blowing air at high pressure over it on a chain board conveyor. Along the way, spraying of anti-static solution occurs to avoid clinging to each other.
Finally, the dry, treated staple fiber is ready for packaging. It enters the baler chamber for weighing and baling. The machine weighs it, while the staff puts into bales and labels it. The forklift transfers complete bales to the storage for shipping.
The manufacture of polyester Staple fiber calls for attention to detail. It is a work of art. By employing modern technology, high-quality polyester products are born. One must understand what goes in and comes out of the production line to contrast quality.