Das Geheimnis der Masken

Das Geheimnis der Produktionslinie hinter einer Maske

 

Viele Menschen wissen nicht, dass die Struktur und der Produktionsprozess hinter einer im Leben üblichen Operationsmaske nicht einfach sind.

Im Allgemeinen bestehen medizinische Masken aus mindestens drei Schichten. Übliche medizinische Einwegmasken bestehen hauptsächlich aus drei Schichten von Vliesstoffe. Die innerste Schicht besteht aus gesponnenem Vliesstoffe. Das mit Acrylschmelze geblasene Vlies ist der Kern der Maske, die äußerste Schicht ist ein Vlies mit einer wasserdichten Behandlung. Sie wird die hauptsächlich zum Isolieren des gesprühten Sprays verwendet.

 

 

 

Branchenkennern zufolge sind Polypropylen (PP) -Partikel aus Erdöl. Es ist die hauptsächlich von Sinopec, PetroChina und CNOOC raffiniert werden. Der am weitesten vorgelagerte Rohstoff für medizinische Masken. Polypropylen kann zur Herstellung von Kunststoffen verwendet werden, von denen ein Teil zur Herstellung von Polypropylenfasern verwendet wird. Zu den Herstellern gehört die One Series von Unternehmen des Sinopec-Systems. Weiter unten sind Polypropylenfasern erforderlich, um Non woven herzustellen.

Die Vorstellung ist eine Kette der medizinischen Maskenindustrie umrissen. Es ist ersichtlich, dass eine Maske viele Produktionsprozesse durchläuft: Der Upstream ist ein Chemieunternehmen → ein Textilunternehmen im mittleren Bereich → ein Downstream-Maskenhersteller. Und die Verbraucher möchten Masken kaufen. Alles, was sie brauchen, ist der reibungslose Betrieb jedes Glieds der gesamten Industriekette. Der Materialteil, der sich auf die Qualität der Maske bezieht, ist auch der kritischste Vliesstoff.

Statistiken zeigen, dass China als weltweit größter Vliesstoffe  im Jahr 2018. Rund 5,94 Millionen Tonnen Vliesstoffe produzierte. Unter der epidemischen Situation wurden jedoch die Schwierigkeiten in der Lieferkette der Maskenherstellung im Textilversorgungsglied im mittleren Bereich abgeschnitten.

 

 

 

 

 

 

 

 

 

 

Melt Blown

Meltblown cloth, commonly known as the “heart” of the masks. It is the filter layer in the middle of the mask, which can filter bacteria and prevent the spread of germs. Melt-blown cloth is a film made of polypropylene with a high melt index. It is a film formed by laminating many criss-cross fibers in random directions. The fiber diameter ranges from 0.5 to 10 microns, and the fiber diameter is about 30 cents of the hair thread.
   
The melt blown process is a nonwoven manufacturing system. It is  involving direct conversion of a polymer into continuous filaments, integrated with the conversion of the filaments into a random laid nonwoven fabric.
The melt blown process  is a one-step process that converts polymer resin into low diameter fiber nonwoven web or tow (Andreas Desch, February 2011). The melt blown process, and its variants, is the only large-scale commercial process. It is presently being used to directly produce melt spun fibers with diameters in the submicron range without splitting or chemically dissolving away polymer.
Melt Blown Made in Germany
There couple of manufacture that produce melt blown in Germany. However, their orders are queued unitl September!

Talk About Melt Blown

 

Almost 500,000 tons of nonwovens are currently used annually in the production of filters, which corresponds to approx. 10% of current worldwide industrial nonwovens manufactured. Here, the filter market is split into 2 areas: airand liquid filtration. While in excess of 170,000 tons of nonwovens were manufactured for gas/air filters in 2015, the volume for liquid filters was almost double at around 295,000 tons.

Melt blowing is a conventional fabrication method of micro- and nanofibers where a polymer melt is extruded through small nozzles surrounded by high speed blowing gas. The randomly deposited fibers form a nonwoven sheet product applicable for filtration, sorbents, apparels and drug delivery systems. The substantial benefits of melt blowing are simplicity, high specific productivity and solvent-free operation. Choosing an appropriate combination of polymers with optimized rheological and surface properties, scientists have been able to produce melt-blown fibers with an average diameter of down to 36 nm.

History

During volcanic activity a fibrous material may be drawn by vigorous wind from molten basaltic magma called Pele’s hair. The same phenomenon applies for melt blowing of polymers. The first research on melt blowing was a naval attempt in the USA to produce fine filtration materials for radiation measurements on drone aircraft in the 1950s. Later on, Exxon Corporation developed the first industrial process based on the melt blowing principle with high throughput levels.China produces 40% of the non-woven fabric in the world with the majority produced in Hebei , Shandong and Jiangxi province.

 

Uses

The main uses of melt-blown nonwovens and other innovative approaches are as follows.

Filtration

Nonwoven melt-blown fabrics are porous. As a result, they can filter liquids and gases. Their applications include water treatment, masks, and air-conditioning filters.

 

Hygiene products

The high absorption of melt-blown fabrics is exploited in disposable diapers and feminine hygiene products.

Meltblown VS PP Spunbond Nonwoven

Melt blowing

Melt blowing is a conventional fabrication method of micro- and nanofibers where a polymer melt is extruded through small nozzles surrounded by high speed blowing gas. The randomly deposited fibers form a nonwoven sheet product applicable for filtration, sorbents, apparels and drug delivery systems. The substantial benefits of melt blowing are simplicity, high specific productivity and solvent-free operation. Choosing an appropriate combination of polymers with optimized rheological and surface properties, scientists have been able to produce melt-blown fibers with an average diameter of down to 36 nm.

The meltblown process is, in many ways, a phenomenon. The variables of the meltblown process are complex because of the many parameters and interrelationships between variables. The quality of the equipment, the selection of the polymer, and the parameter settings all contribute to the quality of the end product. This paper discusses a general trending of these variables. The trends were found to be nonlinear with the exception of two, Bresee and Qureshi (2004) and Lee and Wadsworth (1990). Bresee and Qureshi stated the effect of DCD on pore structure was linear and Lee and Wadsworth stated the effect of DCD on air permeability was also linear. While there has been considerable research conducted on the meltblown process, there are several variables which should be studied further.

 

 

 

PP Spun Bond  Nonwoven Fabric

PP Spun bond non-woven fabrics is one of types of spunbond polypropylene fabric. They are mainly used for outer and inner materials of surgical and hyginene face mask. Because of its softness, environmental protection and practicability. It is often used to make surgical masks, medical cloth, round caps, and various protective face masks, household face masks. It is also used in other medical and health industry and back fabric of other non-woven fabrics.

The non-woven face masks are used to prevent the spread of influenza in spring and seasonal pollen allergies. It brings great convenience to family life and increases people’s comfort in life.

Mask Material Matters

                                           

                                                  




Fashion companies from H&M and Zara to luxury firms LVMH, Kering, and Prada are contributing to the fight against Covid-19 by pledging to supply protective items for medical workers.

Not All Masks Are Equal.

Many fashion brands start to making maks by using whatever material in hand. Are these masks helping to block? Medical-grade masks are made from specialized textiles. The variety favored in places such as hospitals (pdf) today isn’t woven like a typical fabric. It’s made by complex and expensive machines that form melted, synthetic fibers into an extremely fine web. This web allows air to pass through while filtering out particles, which is why this non-woven material is used in respirators such as those labeled N95 in the US or FFP2 in Europe (pdf). The labels refer to the certification processes the respirators undergo. N95 respirators, which are designed to fit so they form a seal around the nose and mouth, can block at least 95% of particles as small as 0.3 microns under testing.

Non Woven PP is never being so popular

So, why is the non-woven propylene material so popular?

The reason why polypropylene non woven masks are favored, mainly because it has the following advantages: good ventilation, non woven fabric breathable than other fabrics, and if the non woven fabric with filter paper in it, it’s filtering will be better; at the same time, non woven masks thermal insulation than ordinary masks, its water absorption, waterproof good effect; In addition, non-woven mask has good scalability, stretching even if it will not appear disheveled phenomenon , Its feel good, very soft, even if washed several times in the sun will not harden. Non woven masks flexible, long-term use can return to its original shape.

If you need the source of PP Non Woven for your mask, write to us.

info@loopmatters.de

Or drop us message at:

https://loopmatters.de/contact/ 

From Coffee To Fabric

Globally, coffee production is estimated to be responsible for upwards of 23 million tons of waste per year. As long as you drink coffee, coffee grounds will naturally be produced, which provides a wide range of raw material production for the production of coffee yarn.

The process is to use super-critical extraction technology-supercritical carbon dioxide extraction technology, to extract the coffee grounds into coffee yarn masterbatch, and then make coffee yarn into clothes.To reuse these waste and turn them into value can be very promising. This will be another great green resource.

What are the benefits of these ‘ coffee fabric’?

1. Odor Control

The coffee fabric absorbs strongly odors that your body produces throughout the day.

Comparing to Cotton:

Cotton Odor Control : 1
Coffee Fabric: 3

2. Fast Drying

The coffee fabric continually moves moisture away
the outer surface of the fabric, hence it also making the drying process fast.

The performance of coffee ground fabric in compared to cotton:
Cotton: 1
Coffee Fabric: 1.88

3. UV Protection

The coffee ground creates a long-lasting natural shield for fiber, reflecting UV rays and hence provide a protection from UV.

4. Ice Cool Touch

The coffee ground is one alternative green fiber. It is with the capability to cool down the temperature of our skin about 1 to 2 degree compared to common fabrics.

Besides, COFFEE GROUNDS OFFER GREENER WAY TO DYE FABRIC BROWN.
One disadvantage of natural dyeing is that it’s hard to measure the quantity needed to get the exact same color,” “For each batch of dye, there may be a difference in the type of beans or maybe the coffee was brewed twice. Creating an exact match is a challenge, especially for manufacturers.”

Concerns over color consistency may fade as consumer attitudes change. If there is greater demand for clothing made with natural dyes, consumers may accept the uniqueness natural dyes create.

Zero Water Fabric

The cheap mass production and final disposal of textiles has pumped hazardous substances in the air, polluted ground and drinking water and created toxic landfills with process chemicals destroying the environment and negatively impacting human health. Challenged by the Greenpeace DETOX campaign to clean up its act, the industry has committed to achieve a “Zero Discharge of Hazardous Chemicals” (ZDHC) in the textile and footwear supply chain by 2020.
Second only to oil companies, the textile industry is one of the dirtiest in the world in terms of its use of hazardous chemicals. The industry uses over five trillion liters of water – the equivalent of two million Olympic-size swimming pools – to dye some 28 billion kg of textiles each year. It has been estimated that approximately 20% of industrial water pollution is the direct result of the dyeing and treatment of textiles. Air pollution and waste landfills compound the problem, contaminating air and soil to enormous effect.

Nano technology

This product is a polymer nanometer integrated additive. Mixing this product with dye can directly achieve the results of traditional printing and dyeing processes and have better results.
Product Features: Can penetrate dyes into fibers, compared with similar additives in the current market. Comparison: penetration, stronger color fastness (test report can be provided), 0 sewage discharge (emphasis); compared with traditional printing and dyeing, fabric penetration is higher , Color fastness is higher than the traditional 0.5 or more, not easy to fade, reduce equipment costs, labor costs.
Fabrics currently in trial: polyester, continue to develop different fabric applications

Sustainable Fashion Matters

Today, sustainability has become a buzzword and turned a few heads. Just as consumers today are taking a closer look at the food they consume and the chemicals they put into their bodies, they are also shifting their purchasing decisions to create a cleaner environment through the clothes they wear.

Instead of buying clothers from fast fashion, more and more consumers begin to think about conscious buying. The voice to buy less and make it last becomes louder and louder.

Keyword: #sustainablefashionmatters

According to Business Insider, the fashion industry produces 10% of all humanity’s carbon emissions, is the second-largest consumer of the world’s water supply, and pollutes the oceans with microplastics.

This year, globally Zara closed its numerous shops and Forever 21 went bankrupt. It seems the fast fashion is being on the edge.

On the other hand, we are seeing more brands taking actions by creating stuff from trash. Prada is the pioneer. Prada Has Signed A Deal That Incentivises It To Be More Eco-Friendly In An Industry First.

“Brands have started integrating the philosophy of ‘doing business for good’ into their values, moving beyond a pure focus on shorter-term shareholder value generation,” according to According to Achim Berg, global leader of consulting firm McKinsey’s apparel, fashion and luxury group.

To use sustainable materials doest make a brand necessarily sustainable. To be considered genuinely sustainable, brands may need to entirely transform every aspect of their businesses. This covers:

Carbon neutral, ensured working conditions and environment, and fair trade. The brands should keep the consumers conscious and make even the resources and supply chain transparency.