In recent years, calcium carbonate-based filler masterbatch has been widely used in the production of plastics and non-woven fabrics. In a short period of time, non-woven fabric enterprises across the country have developed rapidly, and the business is booming and fiercely competitive.

An important reason for the rapid development of PP spunbonded nonwovens is that their manufacturing methods are simple and quick, the product cost is low, the quality is stable, and the market is competitive.

In order to reduce the amount of polypropylene and reduce carbon dioxide emissions, producers also add calcium carbonate filler masterbatch in the production process to occupy more advantages in terms of price, processing, production cost and physical indicators. From this point of view, the application field and sustainable development of PP spunbonded non-woven fabrics have been greatly expanded, and energy saving and emission reduction is an inevitable trend in the development of the spunbond nonwoven fabric industry.

Today, Xiaobian will introduce the process and application of calcium carbonate in non-woven fabrics!

Calcium carbonate in PP spunbonded nonwoven fabric Manufacturing process

The raw material used in the production of spunbonded non-woven fabric is high-melting index polypropylene, which is uniformly mixed with the calcium carbonate filling masterbatch. The hopper enters the screw extruder and is squeezed and melted, then enters the continuous pre-filter and enters the spinning box. .

The melt enters the spinning head through the metering pump, and the metering pump accurately measures the melt to be quantitatively conveyed to the spinneret, and forms a continuous melt flow through the spinning holes, that is, the nascent fiber.

The nascent fibers are then cooled by quenching air and drafted to form a filament bundle. The filament bundle is reciprocally oscillated by a pendulum roller and evenly laid on a running web curtain to form a web.

Why use calcium carbonate as a filler masterbatch?

Calcium carbonate is an extremely important inorganic chemical product widely used in plastics, rubber, paint, paper and other industries. The characteristics of several fillers currently used in the industry are as follows:

Calcium carbonate: The purpose of adding filler masterbatch to the spunbonded nonwoven fabric is to reduce the cost. From the experience of plastic resin modification function and cost reduction, it is the most inexpensive and easy to obtain, and the appearance is white and odorless powder. The relative density is 2.71, the refractive index is 1.65, and the Mohs hardness is 3.

Old earth: easy to disperse, relatively higher than the price of calcium carbonate, the appearance is also white, the relative density is 2.6, the refractive index is 1.56.

Talc powder: easy to disperse, has certain lubricity to the equipment during processing, and is a white powder with solid crystal. I think the density is between 2.7 and 2.8, and the price is relatively expensive.

Mica powder: Relatively low whiteness, because mica powder is non-toxic and can be used in food contact products, the relative density is between 2.8 and 3.0, the refractive index is 1.59, and the Mohs hardness is 3.

Wollastonite: relative density 2.9, refractive index of 1.63, Mohs hardness of 4.5, the biggest advantage is that it does not absorb moisture, and has little effect on the color masterbatch.

Therefore, in the process of making non-woven fabrics, the fillers are generally selected mainly in the form of calcium carbonate. The addition of a little old earth or wollastonite in the production process increases the dispersibility and transparency.

Generally, the number of calcium carbonate is more than 1500 mesh, and it should not be too fine, because the price of too fine mesh is high, and the ultrafine powder is generally not dispersed.

Filling method of filler

The filler is placed in the hopper of the masterbatch without changing the production equipment and production process conditions, but the addition ratio is also limited.

Some manufacturers add a larger hopper and feeder to deliberately add filler. The maximum amount of pellets added is about 20%, and the powder is about 8%.

Now some manufacturers add one or several mixers to mix the materials evenly and then manually put them into the hopper, which is relatively uniform. The addition ratio is as high as 30%, and the powder can reach about 15%.

Some manufacturers stir evenly and then suck into the hopper, the degree of uniformity is relatively poor, but it can also be added to 20% to 30%.

Since the filling of the masterbatch is cost-reducing, the higher the filler concentration in the filler masterbatch, the lower the cost and the less the user is added. Conversely, the lower the concentration, the higher the cost, and the more users add. Moreover, the production functional masterbatch cannot be filled with the masterbatch so as not to affect its functionality.

Yancheng Ruize Masterbatch Co., Ltd. mainly produces and operates: Non-woven masterbatch, Non-woven antibacterial masterbatch,antistatic masterbatch, polypropylene filament masterbatch, Polypropylene filament masterbatch, Non-woven masterbatch,  polypropylene spunbond non-woven masterbatch, Polypropylene fiber masterbatch, chemical masterbatch, Non-woven masterbatch, polypropylene masterbatch, Soft hydrophilic masterbatch.