Problem

A “man-made” fiber spinning plant produces thousands of individual threads simultaneously. All threads come from a polymer melt, which is provided with a very high viscosity, high pressure, and high temperature. This melt is fed through a complex network of distribution lines to the individual spinning heads.
Due to the high viscosity in plastic melt systems, there is generally a laminar flow system. This results in large radial temperature gradients, making it difficult to control the homogeneity of the melt and the strength of the fibers. A thread break very often leads to system downtimes and thus production losses. The product quality is also not constant and this leads to problems during further processing.

Result

The increased attention that was paid to the mixture resulted in a constant yarn with optimal physical properties in spinning mills around the world. The improved control of the temperature enables the spinning of ever-thinner threads. The mechanical strength is improved, the tearing of the threads is reduced, the production is increased and the transition times for color changes are shortened.

Solution

The Statiflo mixers of the 700 series have been specially developed for applications in polymer melting processes. The mixing element is soldered without gaps into the housing made of solid material. This construction prevents unwanted side flows and conveys the polymer flow completely through the static mixer. Furthermore, this construction provides mechanical strength at relatively high pressures. The mixer cannot be pushed out of the pipeline as with other manufacturers.
The mixer housing is customized to the existing pipeline. Reductions can thus be avoided. We deliver surfaces up to Ra = 0.05µ. In the laminar flow area, the mixing effect arises through flow division and radial mixing. This eliminates radial temperature gradients in the polymer melt.
The mixers are used directly in front of the flow division in the distribution system in order to further branch a homogeneous polymer melt. (See markings on the drawing on page 1) With media that stick in this way, a very high surface quality is required so that the melt flow remains efficient and does not remain on the pipe wall and thus negatively influence the mixing result.

Advantages of this special application

• Safe and reliable
• Low acquisition costs
• No moving parts for maintenance-free operation
• Edge sealed construction for stability and safety
• relatively low-pressure loss
• Eliminates radial gradients
• Self-cleaning
• Custom manufacturing

Further advantages of the Statiflo mixer

• Manufactured in all QA / QC systems.
• Available in all sizes
• Eliminates radial gradients
• Completely self-contained system
• Available in almost all materials
• Low shear rate
• No direct energy input
• Can be installed in pipe bends to save space
• Does not require straight piping after the mixer for optimal performance