Smart Processes of Melt-spinning Nonwoven Production Line

Smart Processes of Melt-spinning Nonwoven Production Line
 
Automation for a spunbond & spunmelt nonwoven production line can be applied to the following processes and equipment:
 
01) Material storage and inventory management of polymers, auxiliaries, additives and packaging items.
 
02) Operation of the pretreatment system (pre-crystalization & drying) for polymer raw materials.
 
03) Distribution and transportation of raw materials during production.
 
04) Adjusting and optimizing process parameters as per specific requirements of each P.O. through material feeding formula expert system to enhance production capacity and reduce energy consumption.
 
05) Melt filter element service cycle warning.
 
06) Melt pressure-speed negative feedback control system and over-pressure protection mechanisms.
 
07) Allocation of the filament web basis weight for each spinning beam in a multi-spinning system production line.
 
08) Spinning component service cycle warning.
 
09) Regulating for the speed and temperature of the quenching air flow.
 
10) Matching of filament drafting speed and suction fan.
 
11) Optimization and adjustment of the web former's speed to nonwoven fabrics’ basis weights.
 
12) Coordination of fiber web and the temperature and line pressure of thermal calender.
 
13) Detection and statistical analysis of spunbond/spunmelt nonwoven fabric’s defects and flaws.
 
14) Analysis and statistics of nonwovens quality inspection data, including quality traceability and predictions of fabric quality tendency.
 
15) Nonwovens winding, i.e. the winder operates in winding tension mode with automatic control, enabling automatic unloading of nonwoven rolls and placement of spare winding shafts.
 
16) Storing, transferring, and conveying jumbo rolls.
 
17) Offline slitting machine featuring an automatic knife setting system, as well as automatic placement, insertion, and extraction of winding shafts.
 
18) Preparation of finishing solutions and optimization of operational parameters for after-treatment lines.
 
19) Sorting, stacking, weighing, labeling, and packaging sub-roll nonwovens.
 
20) Nonwoven fabric rolls stacking and warehousing.
 
21) Real-time monitoring of lubrication status and faults of production line equipment, with self-diagnosis and early warning capabilities.
 
22) Efficiently manage end products, materials, and energy consumption. Count and analyze direct production costs of orders in real time, provide accurate feedback for financial calculations, and achieve digital management.
 
23) Real-time monitoring of energy consumption, alarms on abnormalities, and utilizing differences in TOU electricity prices to lower energy costs based on the unit energy consumption of different products.
 
24) Streamline order classification and integration, optimize production scheduling and minimize production changes to reduce production costs.
 
25) Management of equipment spare parts and low-value consumables.
 
26) Inspection of the effectiveness and running status of safety protection devices on the production line.
 
27) Logs and operating status of environmental protection equipment.
 
Benefits of Smart Manufacturing
 
The intelligent production system is an advanced management approach that utilizes technologies of digitization, automation, sensor, information, network, as well as modern management and manufacturing techniques. It optimizes various aspects of production, including site management, quality control, warehouse logistics, financial and human resource management. It transforms the entire process—from the placing of nonwovens orders to end product delivery—into an intelligent, transparent, and digitally integrated system.
 
The intelligent manufacturing system monitors and controls every key aspect of the nonwovens production. It enhances information connectivity between the internal management and field control of the enterprise, while also strengthening the link between nonwovens factories and their customers. This improved management allows companies to better adapt to market demands. As a result, the process becomes more controllable, leading to reduced production costs and resource usage, improved product quality, more accurate delivery times, and ultimately, increased customer satisfaction.
 
The application of intelligent production improves the production environment in several ways. Many routine, repetitive tasks can be automatically handled by systems or equipment, which decreases reliance on manual labor and lessens the physical demands on employees. This reduction in human intervention in the production process ultimately leads to lower labor costs. Additionally, improved communication and connectivity between various stages of production enhances execution, strengthens cohesion within the enterprise, and boosts competitive advantage, resulting in direct economic benefits.
 
Typical costs for nonwoven fabric production companies include material costs, energy expenses, labor costs, equipment depreciation, financial expenses, sales costs, and taxes. All of these items can be monitored and controlled by intelligent management systems. Implementing such systems can lead to reduced material consumption, energy savings, lowered labor expenditures, decreased equipment management costs, and significant economic benefits for businesses.
Smart Processes of Melt-spinning Nonwoven Production Line
 
Automation for a spunbond & spunmelt nonwoven production line can be applied to the following processes and equipment:
 
01) Material storage and inventory management of polymers, auxiliaries, additives and packaging items.
 
02) Operation of the pretreatment system (pre-crystalization & drying) for polymer raw materials.
 
03) Distribution and transportation of raw materials during production.
 
04) Adjusting and optimizing process parameters as per specific requirements of each P.O. through material feeding formula expert system to enhance production capacity and reduce energy consumption.
 
05) Melt filter element service cycle warning.
 
06) Melt pressure-speed negative feedback control system and over-pressure protection mechanisms.
 
07) Allocation of the filament web basis weight for each spinning beam in a multi-spinning system production line.
 
08) Spinning component service cycle warning.
 
09) Regulating for the speed and temperature of the quenching air flow.
 
10) Matching of filament drafting speed and suction fan.
 
11) Optimization and adjustment of the web former's speed to nonwoven fabrics’ basis weights.
 
12) Coordination of fiber web and the temperature and line pressure of thermal calender.
 
13) Detection and statistical analysis of spunbond/spunmelt nonwoven fabric’s defects and flaws.
 
14) Analysis and statistics of nonwovens quality inspection data, including quality traceability and predictions of fabric quality tendency.
 
15) Nonwovens winding, i.e. the winder operates in winding tension mode with automatic control, enabling automatic unloading of nonwoven rolls and placement of spare winding shafts.
 
16) Storing, transferring, and conveying jumbo rolls.
 
17) Offline slitting machine featuring an automatic knife setting system, as well as automatic placement, insertion, and extraction of winding shafts.
 
18) Preparation of finishing solutions and optimization of operational parameters for after-treatment lines.
 
19) Sorting, stacking, weighing, labeling, and packaging sub-roll nonwovens.
 
20) Nonwoven fabric rolls stacking and warehousing.
 
21) Real-time monitoring of lubrication status and faults of production line equipment, with self-diagnosis and early warning capabilities.
 
22) Efficiently manage end products, materials, and energy consumption. Count and analyze direct production costs of orders in real time, provide accurate feedback for financial calculations, and achieve digital management.
 
23) Real-time monitoring of energy consumption, alarms on abnormalities, and utilizing differences in TOU electricity prices to lower energy costs based on the unit energy consumption of different products.
 
24) Streamline order classification and integration, optimize production scheduling and minimize production changes to reduce production costs.
 
25) Management of equipment spare parts and low-value consumables.
 
26) Inspection of the effectiveness and running status of safety protection devices on the production line.
 
27) Logs and operating status of environmental protection equipment.
 
Benefits of Smart Manufacturing
 
The intelligent production system is an advanced management approach that utilizes technologies of digitization, automation, sensor, information, network, as well as modern management and manufacturing techniques. It optimizes various aspects of production, including site management, quality control, warehouse logistics, financial and human resource management. It transforms the entire process—from the placing of nonwovens orders to end product delivery—into an intelligent, transparent, and digitally integrated system.
 
The intelligent manufacturing system monitors and controls every key aspect of the nonwovens production. It enhances information connectivity between the internal management and field control of the enterprise, while also strengthening the link between nonwovens factories and their customers. This improved management allows companies to better adapt to market demands. As a result, the process becomes more controllable, leading to reduced production costs and resource usage, improved product quality, more accurate delivery times, and ultimately, increased customer satisfaction.
 
The application of intelligent production improves the production environment in several ways. Many routine, repetitive tasks can be automatically handled by systems or equipment, which decreases reliance on manual labor and lessens the physical demands on employees. This reduction in human intervention in the production process ultimately leads to lower labor costs. Additionally, improved communication and connectivity between various stages of production enhances execution, strengthens cohesion within the enterprise, and boosts competitive advantage, resulting in direct economic benefits.
 
Typical costs for nonwoven fabric production companies include material costs, energy expenses, labor costs, equipment depreciation, financial expenses, sales costs, and taxes. All of these items can be monitored and controlled by intelligent management systems. Implementing such systems can lead to reduced material consumption, energy savings, lowered labor expenditures, decreased equipment management costs, and significant economic benefits for businesses.