Hubei Decon uses antimony-free catalysts with independent intellectual property rights to successfully develop three specifications of environmentally friendly antimony-free low-melting polyester chips at 180℃, 200℃, and 220℃, realizing serial production of low-melting polyester products. New breakthroughs have been made in strengthening the polyester industry chain and improving the company’s production efficiency.
“In the past, only one product was developed and produced at a time. This time, three products were continuously developed and produced. It is rare in the industry to challenge the production process with such a difficult differentiated production.”
Low melt chips are used in composite spinning fibers, high-end non-woven, and other fabrics. They can be used to produce skin-core composite short yarns and filaments, which can be used to produce filters, clothing, shoes, hats, sleeping bags, sofas, bedding, health and personal care, and also raw materials for medical and sanitary products. Due to the addition of an antimony-free catalyst, the environmental protection performance is prominent, and it is favored by the market.
Yichang Zhongying polyester plant was completed and put into production in 2010. It was originally designed to produce conventional semi-dull polyester chips and does not have the conditions for producing differentiated products.
It is very difficult to produce items such as low melting point chips. As a result, the company’s polyester differentiated R&D team has risen to the difficulties and carried out technical research. To manufacture chips with different melting points on one production line, there are strict requirements for adjustment and optimization of process parameters, stable product quality, transitional material control, and batch switching of finished goods.
In the production process, the polymerization reaction becomes more complicated due to the simultaneous addition of the third and fourth monomer raw materials. Because there was no previous experience to learn from, the technicians tried repeatedly and finally figured out the matching production technology and product quality control methods. In order to reduce the production of transitional materials during conversion, they actuarially calculated the amount of various raw materials added, strictly controlled the timing of addition, and rationally arranged variety switching to minimize costs. In order to ensure the stability of the overall production process, the technicians kept an eye on the scene for three consecutive days and two nights. On January 19, three specifications of antimony-free low-melting polyester chips totaling 300 tons were successfully rolled off the production line and passed the inspection once.
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