OPTMIZATION OF ADDITVE ADDITION TO

POLYPROPYLENE SPUN BONDED NON WOVEN

A Project Report

Submitted by

JAIKISHAN C. (20062513)

MURUGAVEL A. (20062520)

in partial fulfillment for the award of the degree

of

BACHELOR OF TECHNOLOGY

in

TEXTILE TECHONLOGY

A.C COLLEGE OF TECHNOLOGY

DEPARTMENT OF TEXTILE TECHNOLOGY

ANNA UNIVERSITY CHENNAI

CHENNAI 600 025

MAY 2010
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ANNA UNIVERSITY CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “OPTMIZATION OF ADDITIVE ADDITION TO

POLYPROPYLENE SPUN BONDED NON WOVEN” is the bonafide work of
JAIKISHAN, C. and MURUGAVEL, A. who carried out the project work under my
supervision. Certified further, that to the best of my knowledge the work reported
herein does not form part of any other project work/thesis or dissertation on the basis
of which a degree or award was conferred on an earlier occasion these or any other
candidate.

Dr. N. SELVAKUMAR Dr. M. MATHUSOOTHANAN

PROFESSOR AND HEAD SUPERVISOR

Department of Textile Technology Department of Textile Technology
Anna University Chennai Anna University Chennai
Chennai – 600 025 Chennai – 600 025
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ABSTRACT

The main objective of this work is to find out the maximum amount of additve

(CaO+LDPE) that can be added to virgin Polypropylene (PP) in the production of

spun bonded fabric for low end applications like covers etc.,

This work was carried out in an industrial unit which was producing spun

bonded non wovens wherein 20% of additve was normally added to virgin

Polypropylene. It was observed that the amount of additve can be increased safely

upto 27.5% without any significant changes in the mechanical properties like tensile

strength or tear strength. The bending properties of the fabric seems to be affected

with the increase in additve content in the spun bonded non-woven.

The increase in additve content will result in substantial savings in the long run.
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ACKNOWLEDGEMENT

We place on record our profound and indebtedness to our guide Dr. M.

Mathusoothanan, Professor, Department of Textile Technology, for his valuable

suggestions and guidance throughout the project.

We are extremely grateful to Dr. N. Selva Kumar, Professor and Head of the

Department of Textile Technology, for his support by giving us the full freedom to

carry out the project in the Department.

We convey our sincere thanks to Mr. Deepak Reddy, Managing Director,

Sinecera Pvt. Ltd and Mr. Nehru, Chief executive, Sinecera Pvt. Ltd for carrying out

our project.

Last but not the least, I would like to extend my gratitude to all the other

faculty members, technical staff, student friends and research scholars belonging to

the textile and other departments for their support and encouragement.

JAIKISHAN C. MURUGAVEL A.

TABLE OF CONTENTS
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CHAPTER NO. TITLE PAGE No.

ABSTRACT iii
ACKNOWLEDGEMENT iv
LIST OF TABLES viii
LIST OF FIGURES ix
1 INTRODUCTION 1

1.1 Introduction of Non-woven industry 1

1.2 Application 2

2 LITERATURE REVIEW 4
2.1 INTRODUCTION 4
2.2 WEB 4
2.2.1 Parallel laid web 4
2.2.2 Cross laid web 5
2.2.3 Random laid web 5
2.2.4 Web formed by staple fibres 6
2.2.4.1 Parallel laid web formed
6
by staple fibres
2.2.4.2 Random laid web formed by
6
staple fibres
2.2.4.3 Cross laid web formed by
6
staple fibres
2.2.5 Web formed by Filaments 7
7
2.2.6 Web formed by Wet Laid method

2.3 BONDING 8
2.3.1 Mechanical bonding 8
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2.3.1.1 Needling 8
2.3.1.2 Stitch bonding 9
2.3.1.3 Spun laced 9
2.3.2 Thermal Bonding 10
2.3.2.1 Conduction type heater 10
2.3.2.2 Convection type heater 10
2.3.3 Chemical bonding 11
2.4 NON WOVEN FROM POLYMERS 12
2.4.1 Melt blown process 12
2.4.2 Spun bonding 12
2.5 FIBRES USED IN SPUN BONDING 13
2.5.1 Polypropylene 13
2.5.2 Polyester 14
2.5.3 Nylon 14
2.6 SPUN BOND PROCESS SYSTEM 15
2.6.1 Docan system 15
2.6.2 Reicofil system 16
2.7 RESEARCHES CARRIED OUT IN SPUN
18
BONDING OF POLYPROPYLENE
2.7.1 Interfacial Adhesion 18
2.7.2 Mechanical Anchoring 18
2.8 ROLE OF ADDITIVES 18

2.9 SUMMARY 20

3 MATERIAL AND METHODS 21

3.1 INDUSTRIAL UNIT 21
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3.2 SPUN BONDING MACHINE 22

3.3 PROCESS FLOW 22
3.4 PROBLEMS FACED BY THE INDUSTRY 23
3.5 METHODOLOGY 23
3.6 ASSESSMENT OF FABRICS 24
3.7 TENSILE PROPERTIES 24
3.8 BENDING RIGIDITY 24
3.9 TEAR STRENGTH 25
4 RESULT AND DISCUSSION 26
4.1 TEAR STRENGTH PROPERTIES 26
4.1.1 Significance level test 27
4.1.2 Discussion 28
4.2 BENDING LENGTH PROPERTIES 29
4.2.1 Significance level test 30
4.2.2 Discussion 31
4.3 TENSILE PROPERTIES 31
4.3.1 Significance level test 33
4.3.2 Discussion 34
5 SUMMARY AND CONCLUSION 35
5.1 CONCLUSION 35
5.2 FUTURE SCOPE OF THE PROJECT 36
REFRENCES 37
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LIST OF TABLES

TABLE NO. TITLE PAGE NO.

4.1 TEAR STRENGTH PROPERTIES 26
4.2 BENDING PROPERTIES
29

4.3 TENSILE PROPERTIES 32

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LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

2.1 DOCAN SYSTEM 16
2.2 RECOFIL SYSTEM 17
3.1 SPUN BONDING PROCESS 22

3.2 PROCESS FLOW 23

4.1 TEAR STRENGTH VS MIXING RATIO 27
4.2 BENDING RIGIDITY VS MIXING RATIO 30
4.3 BREAKING LOAD VS MIXING RATIO 32