Market Background & Challenges

In the competitive industrial brush manufacturing sector, producing high-quality nylon or polypropylene (PP) filaments requires rigorous control over diameter consistency and tensile strength. Manufacturers face the challenge of maintaining output stability under continuous 24/7 operating conditions while minimizing material waste caused by fluctuations in melt pressure or temperature.

Customer Application & Scenarios

The client is a large-scale manufacturer of cleaning consumables specializing in heavy-duty filaments for industrial sweepers and automated scrubbers. Their primary objective was to upgrade to a production line capable of handling high-volume output without compromising the mechanical integrity of the monofilaments. Specifically, they required a solution that eliminates filament breakage during high-speed stretching and ensures uniform crimping for subsequent processing.

Our Solution: The RS-90×30-900 Extruding Line

To meet these technical demands, the RS-90×30-900 unit was deployed. This 48-meter-long production line integrates precision engineering with automated feedback loops to guarantee reliable performance.

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  Precision Extrusion System: The unit features a 90mm diameter screw with a 30:1 L/D ratio, driven by a 45KW Siemens frequency-controlled motor to ensure a stable and homogeneous melt.

   

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  Automated Diameter Control: A closed-loop system utilizes Shanghai Zhaohui pressure sensors and a melt pump (30CC×2) to automatically adjust screw speed based on real-time pressure changes, ensuring uniform filament diameter.

   

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  High-Strength Stretching: The line incorporates four stages of seven-roller stretching units. Units B, C, and D provide a maximum drafting force of 1000 daN, supported by American TIMKEN-TWB high-precision bearings and Guomao hard-tooth reducers for vibration-free operation.

   

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  Thermal Consistency: The 4500mm double-layer hot blast ovens and overflow-type hot water tanks utilize special air channel designs and SSR temperature control to minimize temperature variance, which is critical for the filament's molecular orientation and elasticity.

   

Technical Specifications Summary

The following table highlights the parameterized evidence of the system's capacity:

Feedback & Conclusion

Since the installation of the RS-90×30-900 line, the client has reported a significant reduction in filament diameter deviation and a marked increase in the wear resistance of their industrial brushes. By utilizing a stabilized extrusion process and high-torque stretching, the production line maintains an optimal balance between high output and technical precision. The integration of high-end components like Siemens motors and TIMKEN bearings ensures long-term reliability in demanding industrial environments.