FARÉ SuperStaple III
This line evolved from the success we developed with the SuperStaple II line. This line, in addition to spinning standard fibers of a single component, can spin bicomponent sheath-core fibers of either concentric or non-concentric cross sections. Bicomponent fibers have superior bonding capabilities and are therefore of greater value in high speed thermobonding, air-laid and spunlacing applications.
One of the more recent developments includes the ability to extrude fiber directly from pre-washed bottle flakes, without the time consuming and expensive process of drying. This new system reduces power consumption by as much as 0.7 to 0.9 kW/pound (1.5 to 2.0 kW/kg)!
In all of its outward appearances, except for the second extruder, the FARE SuperStaple III (three) is the same as the SuperStaple II. The spinning system concept in SuperStaple III utilizes two extruders so as to be alternatively able to process one or two thermoplastic polymers. The melt, respectively the two melts, are fed to the spinning unit by a double manifold.
The materials for processing monocomponent regular fibers are PP, PE, PET and
PA.
A bicomponent fiber is basically composed of two thermoplastic materials with
different melting points (for example PP 165°C, PE 120-130 °C, PA 220°C, PET
260°C, PE 130°C, CO-PET 115°C). A variety of combinations of two materials
are possible: for processing bicomponent fibers: the low melting material in the
sheath and the higher melting material in the core. For example: PE-PP, PE-PET,
PA-PET and individual polymers with their co-polymers (PE-PET and PA-PET only to
be produced by Superstaple III in staple form).
In the major process for manufacturing nonwovens like thermobonding, hot-air,
through-bonding, needle-punching, air-laid, spunlacing, both regular and
bicomponent staple fiber in 100% or in blends of regular and bicomponent fibers
according to the fabric end-use are used. After being heated, the bicomponent
fibers bond to each other, but retain their fibrous structure due to the core
material having a higher melting point than the sheath material.
Superstaple III can be also designed in a special version to produce short cut
regular and bicomponent staple fibers in the titers and cuts as requested for
the air-laid nonwoven process.
The denier range for the Superstaple III is 0.9 to 30.
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