PP Multifilament Yarn
&
HDPE Monofilament Yarn

HDPE Monofilament Yarn

Mono filaments are single threadlike synthetic fibers made of HDPE , PP , Nylon , etc. Monofilament extrusion is a process used to make continuous strands of polymeric material for a variety of consumer and industrial products. Both one and two polymer systems called co-extrusion or bi component extrusion are widely used. Mono filament yarns are usually circular and solid in cross section.

The shape of the filament can be altered to produce non circular and/or hollow filaments. The diameter range of mono filament yarns varies between 100–2000 μm. The apparel applications of mono filaments are limited owing to their low bulk and high bending rigidity. The examples of mono filaments

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from everyday life include fishing line, dental floss, in sports racquets, bristles of tooth brushes, insect nets, agricultural tent houses, fencing wires, etc. Hollow mono filaments are used in softer sewing thread applications where elastomeric mono filaments find applications in pressure garments.

Mono filament fabrics are woven from extruded synthetic filaments produced in diameters from 30μm to 3mm. These fabrics have become important as filter used in a broad range of industries and applications. Generally, HDPE Mono filament Yarns are

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materials that are used for weaving braiding and twisting applications in agro, geo and industrial textiles. It has high Tenacity, Chemical Resistance and Flexibility. Yarn Thickness varies between 0.1mm to 0.7mm (70dr to 3300dr).

Applications of HDPE Monofilament Yarns

Weaving material for agro textiles such as filters, shade nets, industrial textiles & furnishing fabrics.

Braiding material for ropes, fishing nets, fences, rubber bands and strings

Knitting and twisting into safety nets, protection covers, open packaging, & marking materials

Reinforcement material for coating products.

PP Multifilament Yarn

Multifilament yarns are composed of a bundle of very thin, infinitely long threads. The threads are generally referred to as filaments. These yarns are generally spun on vertical machines with filaments extruded out of the spinnerets and air-cooled before getting wound onto spools.In multi filament yarn production,

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each spinneret contains a plurality of holes (usually 30–100) and each hole of the spinneret creates a filament. Hence, multi filament yarns are a collection of extremely fine mono filaments (filament diameter, 10–50 μm). The Multi filament yarns are much more flexible than mono filaments at equivalent linear density and also higher covering power.

Multifilament yarns contain a multitude of fine, continuous filaments (often 5 to 100 individual filaments) usually with some twist in the yarn to facilitate handling. Sizes range from 5–10 denier up to a few hundred denier. Individual filaments in a multifilament yarn are usually about 1–5 denier.
read more PP multi filament yarns ( twisted & Non twisted) with 700 to 4000 deniers has 5.5 to 6.5 GPD ( grams per denier) having good tenacity , high impact stress, water resistant , intermingled & recyclable.

PP yarns are classified into 2 types :

1) BCF stands for “bulked continuous filament” and refers to a one step process where one or multiple filament yarns are tangled by airstream. The end use for BCF yarns is usually carpets as BCF yarns are very bulky. 

2) CF stands for “continuous filament” in which spin finishes yields high- and medium-tenacity yarns which contributes to stable production processes.

Applications of PP Multifilament yarns

Why Bajaj ?

Our Masterbatches for these applications are manufactured with state of the art technology and full fledged RnD lab with Quality control & Assurance to ensure offering our customers best in class , consistent quality with wide range of Color palette besides white & black with well tested colour fastness, gloss with aesthetics & weather ability characteristics.
As the global demand for mono and multi filament yarns keep growing in sectors such as Agriculture, Fishing ,Technical Textiles, Automotive, Waste water treatment, etc , WE at BAJAJ strive hard with our Team to carry on futuristic innovative efforts with confidence in developing our customized masterbatches to cater any customer across the globe in this sector

Unique features

Our masterbatches are suitable for extrusion of all kinds of low or medium density PE filaments with good runnability & pack life.
Colour masterbatches yields high-intensity color with great dispersion due lowest filter pressure value , No migration , withstands high temperatures , free from contamination , no agglomerates , etc.
Enables the processors with ease to choose the right masterbatch from our product basket as low LDR % results in cost optimization.
Additives like UV-blockers makes the filament yarns more resistant to water, chemicals, insects and mildew, sunlight and abrasion. Hence it is compatible with all kinds of outdoor applications.

Trouble shooting guide - HDPE Monofilaments

PROBLEMPOSSIBLE CAUSESSOLUTIONS
Frequent filament breakage at quench bathMoisture in the materialUse hopper dryer.
Contamination in the materialInspet feed, reduce or stop using recycled material
Surging in extruderRun at higher pressure or with better mixing screw, analyse period of surging and relate to drive controllers.
Breakage of particular filaments due to partially blocked holes of extrusion die / spinneret.Clean the die holes for blockage, reduce extrusion temperature if at higher side, check for uneven temperature or material distribution in the extrusion die head which can cause uneven melt flow pattern
Oxidation & weakening of filament surfaceRun at lower temperature or reduce the distance between die head & quench bath.
Melt draw down ratio too highReduce melt draw-down ratio
Quench bath temperature too lowIncrease quench bath temperature to desired level.
Molten filaments sticking to each otherSeparate the filaments properly after quenching.
Melt too cold which reduces ductility.Increase melt temperature
Frequent filament breakage at stretching ovenHigher stretch ratio, low stretching temperature.Optimize stretching parameters, both of these produce excessive tension in the filaments.
Stretching temperature too high.Reduce stretch temperature, if it’s too high it will draw the filaments but without orientation causing filament breaks under normal stretching tension.
Abrasive marks or scratches on godet rolls.Grind them smooth or wrap them with Teflon tapes
Jerks & erratic drive of the godet rolls. Check smoothness of operation for all moving parts.
Non-uniformity of filamentsContaminated polymer meltInspect feed, reduce or stop using recycled material.
Non-uniform dispersion of pigments in polymer meltUse good quality pigments, preferably use base polymer of masterbatch compatible / same as parent material.
Surging in extruderRun at higher pressure or with better mixing screw , check production rate & reduce if running at higher production rate than recommended.
Through-put variationCheck metering pump drive for variation RPM check for agglomerate formation at feed zone.
Broken or cracked filter packChange filter pack, broken filter pack causes uneven melt flow to extrusion die / spinneret.
Temperature variation at extrusion dieCheck for actual & set temperature, check for burnt out heaters.
Check for actual & set temperature, check for burnt out heaters.Maintain quench water temperature at desired level.
Variation in godet speedCheck godet drive for speed variation , jerks.
Jerks & insufficient pressure on nip rolls.Check and adjust pressure on nip rolls.
Poor Surface appearanceMoisture in the material, master batch or pigments.Use hopper dryer at feed section.
Degradation of material in extruder.
Melt fracture.
Reduce extrusion temperature.
Melt fractureReduce extrusion rate, line speed, use larger dia extrusion hole with the higher melt draw down ratio, reduce entrance angle in die holes, increase extrusion temperature.
Lower tenacityLower stretching temperatureIncrease stretching temperature
Lower molecular orientationIncrease stretch ratio, optimise stretching temperature, too high or too low stretching temperature reduce filament tenacity, note that changes of orientation may also change the filament diameter, requiring compensating adjustment elsewhere to maintain desired filament diameter.
Nicks & cuts in filaments
All causes related to non-uniformity of filaments.
Examine broken & unbroken filaments, look for a repetitive pattern & source of defect generation.

Trouble shooting guide - PP Multifilament yarns

PROBLEMPOSSIBLE CAUSESSOLUTIONS
Filament breakages due to degradationMoisture in the material.Use hopper dryer.
Polymer dust/ powder in the material.Use dust free material, eliminate sharp corners in conveying system particularly at hopper valves which generate polymer dust due to abrasion of granules at these sharp corners
High level of low molecular weight component in the material.Use narrow molecular weight distribution material, reduce extrusion temperature.
Pigments / masterbatches degrading at spinning temperature Use high temperature stability pigments / masterbatches.
Higher melt residence time in the extruder / manifoldAdjust melt residence time to optimum level.
Extrusion temperature too highOptimise extrusion temperature profile
Uneven temperature distribution in manifold and spin packCheck heating system, temperature controllers & thermocouples for its working.
Filament breakage at spinneretMelt viscosity is too high or too low.Adjust melt viscosity by optimising extrusion temperature.
Addition of some types of pigments drastically reduce melt viscosity.Use high pressure & temperature stability pigments, reduce extrusion temperature.
Uneven melt flow or formation of channel due to damaged filter pack of spinning head.Replace damaged filter pack, reduce the pressure between extruder & filter pack
Uneven melt flow due to malfunctioning of metering pump.Check metering pump drive system, replace worn out parts of metering pump.
Bits of decomposed material clog spinneret holes.Clean & replace spinneret, check for pigment degradation, reduce spin pack temperature.
Filament breakage at quenching zoneMelt draw down too high creating very high filament tension in spin-line zone.Reduce take-up velocity.
Quench air velocity too high, filaments sticking to each other.Reduce quench air velocity, temperature respectively.
Filamentation at spin finish applicator, worn out thread guidesCheck thread guides for damage / serration, repair / replace spin finish applicator.
Filament breakage at winding zoneJerks, vibrations & erratic drive of godets and winderCheck godet and winder drive for jerks and vibration, repair the same.
Worn out thread guides resulting into filamentation.Replace worn out thread guides.
Non-uniformity of spun filamentsDegradation of material.Use polymer free of moisture & dust. Use hopper dryers & feeders, reduce extrusion temperature, use narrow molecular weight distribution polymers
Non-uniform dispersion of pigments, degradation of pigments.Use high temperature grade pigments, particle size of pigment could be less than 5μm size.
Through-put variation.Check metering pump drive system & replace worn out metering pump parts.
Damaged or choked filter pack causing uneven melt flow.Replace damaged filter pack with new pack.
Temperature variation between various spinning heads resulting into variation in melt viscosity. Check temperature controller and thermo couples, maintain temperature variation between all spinning head within +/- 1degC.
Partial blocking of spinneret holes causing uneven melt flow.Clean the spinnerets holes or replace spinning block with new pack.
Variation in quench air velocity.Check & adjust air blower speed, clean air filters & nets.
Variation in take-up / winding speed.Check AC inverters of godets and winders for their performance.

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