Melt Direct Spinning Masterbatch Adding Equipment: Technical Breakthrough Path for Mixing Uniformity

As a key equipment for the functional upgrading of the chemical fiber industry, melt direct spinning masterbatch adding equipment has the core value of giving specific functions to the fiber by accurately adding masterbatch. In the high-temperature melt spinning process, the equipment mixes the masterbatch containing functional components such as antibacterial agents and color masterbatches with the polymer melt, so that the functional components are evenly distributed inside the fiber, thereby forming a differentiated fiber product with antibacterial deodorization, UV resistance, color stability and other characteristics. However, the premise of this functional transformation is that the masterbatch is evenly dispersed in the melt at the molecular level. ​          Fiber quality defect chain caused by uneven mixing
Insufficient mixing uniformity will cause systematic quality problems in fiber production. In the functional fiber manufacturing scenario, the antibacterial performance of antibacterial fiber depends on the uniform distribution of antibacterial masterbatch. If the mixing capacity of the equipment is insufficient, the local antibacterial agent concentration of the fiber will be too low, and the antibacterial standard required for medical supplies will not be met; in antistatic fiber, the uneven dispersion of conductive masterbatch will make the surface charge of the fiber unable to be effectively conducted, resulting in electrostatic adsorption of the finished textile product. In the production of colored fibers, the dispersion defects of masterbatch are directly manifested as fiber color difference, which destroys the visual consistency of textiles and even causes the whole batch of products to be downgraded due to appearance defects. ​
The decisive role of equipment structure on mixing efficiency​
The structural design of melt direct spinning masterbatch adding equipment directly affects the mixing effect. Traditional single-screw equipment is limited by the material conveying method. When processing high-viscosity polyester melt, the masterbatch and the melt can only achieve surface contact, and it is difficult to break through the viscosity resistance of the melt to achieve deep mixing. The new equipment uses the reverse meshing structure of the twin screws to use the synergistic effect of shear force and tensile force to break the masterbatch into micron-sized particles and embed them into the melt flow; the dynamic mixing agitator is driven by a variable frequency motor to continuously apply eddy current stirring during the melt conveying process, so that the functional components are fully diffused in a turbulent state; the static mixer further eliminates the difference between the melt flow layers through a multi-layer turbulent structure to ensure the uniformity of the composition of the final mixed melt. ​
Process synergy optimization improves quality stability​
The guarantee of mixing uniformity requires deep synergy between equipment and process. The equipment speed parameters need to be dynamically matched with the melt temperature and extrusion speed. Too high speed will aggravate melt degradation, while too low speed will lead to insufficient mixing. The temperature control system needs to accurately control the difference between the masterbatch melting point and the melt temperature to ensure that the masterbatch flows synchronously with the melt in the molten state. Through the closed-loop adjustment of the equipment parameters by the PLC intelligent control system, the rapid switching of different functional masterbatch addition processes can be achieved. When producing different products such as antibacterial fibers and colored fibers, the optimal mixing parameters can be automatically matched to maintain the long-term stability of fiber performance. ​
Quality standards force equipment technology iteration​
With the improvement of fiber performance requirements in application fields, industry quality standards have put forward more stringent assessment indicators for mixing uniformity. The antibacterial persistence test of medical textiles and the color fastness standard of automotive interior fabrics are essentially reverse verifications of the mixing ability of melt direct spinning masterbatch adding equipment. Equipment manufacturers achieve real-time monitoring and feedback adjustment of the mixing process by developing modular mixing units and introducing innovative technologies such as online concentration detection devices, ensuring that the fluctuation of the functional component content of each fiber is controlled within a very small range, thereby meeting the strict requirements of the high-end market for the consistency of fiber product quality.