Overview Process Schematic

Dry spinning is used to form polymeric fibers from solution. The

polymer is dissolved in a volatile solvent and the solution is pumped
through a spinneret (die) with numerous holes (one to thousands). As
the fibers exit the spinneret, air is used to evaporate the solvent so
that the fibers solidify and can be collected on a take-up wheel.
Stretching of the fibers provides for orientation of the polymer chains
along the fiber axis. Cellulose acetate (acetone solvent) is an example
of a polymer which is dry spun commercially in large volumes. Due to
safety and environmental concerns associated with solvent handling
this technique is used only for polymers which cannot be melt spun.

Overview Process Schematic

Melt spinning is the preferred method of manufacture for

polymeric fibers. The polymer is melted and pumped through a
spinneret (die) with numerous holes (one to thousands). The
molten fibers are cooled, solidified, and collected on a take-up
wheel. Stretching of the fibers in both the molten and solid states
provides for orientation of the polymer chains along the fiber
axis. Polymers such as poly(ethylene terephthalate) and nylon
6,6 are melt spun in high volumes.
Spinning is manufacturing process for creating polymer fibers. It is a specialized form of extrusion that
uses a spinneret to form multiple continuous filaments. There are four types of spinning: wet, dry, melt,
and gel spinning.

First, the polymer being spun must be converted into a fluid state. If the polymer is a thermoplastic then
it is just melted, if not then it may be dissolved in a solvent or chemically treated to form soluble or
thermoplastic derivatives. The fluid polymer is then forced through the spinneret, where the polymer
cools to a rubbery state, and then a solidified state.
Types of Spinning
There are different types of spinning. Such as:
Dry Spinning
Wet Spinning
Melt Spinning
Gel Spinning
Now they are described below:

1. Dry Spinning
Dry spinning is also used for fiber-forming substances in solution. However, instead of precipitating the
polymer by dilution or chemical reaction, solidification is achieved by evaporating the solvent in a
stream of air or inert gas.
The filaments do not come in contact with a precipitating liquid, eliminating the need for drying and
easing solvent recovery. This process may be used for the production of acetate, triacetate, acrylic,
modacrylic, PBI, spandex, and vinyon.
2. Wet Spinning
Wet spinning is the oldest process. It is used for fiber-forming substances that have been dissolved in a
solvent. The spinnerets are submerged in a chemical bath and as the filaments emerge they precipitate
from solution and solidify.
 Fig: Principle of wet spinning
Because the solution is extruded directly into the precipitating liquid, this process for making fibers is
called wet spinning. Acrylic, rayon, aramid, modacrylic and spandex can be produced by this process.
3. Melt Spinning
In melt spinning, the fiber-forming substance is melted for extrusion through the spinneret and then
directly solidified by cooling. Nylon, olefin, polyester, saran and sulfar are produced in this manner.
Melt spun fibers can be extruded from the spinneret in different cross-sectional shapes (round, trilobal,
pentagonal, octagonal, and others). Trilobal-shaped fibers reflect more light and give an attractive
sparkle to textiles.

Pentagonal-shaped and hollow fibers, when used in carpet, show less soil and dirt. Octagonal-shaped
fibers offer glitter-free effects. Hollow fibers trap air, creating insulation and provide loft characteristics
equal to, or better than, down.
4. Gel Spinning
Gel spinning is a special process used to obtain high strength or other special fiber properties. The
polymer is not in a true liquid state during extrusion. Not completely separated, as they would be in a
true solution, the polymer chains are bound together at various points in liquid crystal form.
This produces strong inter-chain forces in the resulting filaments that can significantly increase the
tensile strength of the fibers. In addition, the liquid crystals are aligned along the fiber axis by the shear
forces during extrusion. The filaments emerge with an unusually high degree of orientation relative to
each other, further enhancing strength. The process can also be described as dry-wet spinning, since the
filaments first pass through air and then are cooled further in a liquid bath. Some high-strength
polyethylene and aramid fibers are produced by gel spinning.
http://textilelearner.blogspot.com/2012/03/what-is-spinning-types-of-spinning-dry.html

Melt Spinning, Dry spinning and Wet Spinning Method :

Man-made fibers are manufactured by spinning the polymer. There are three major types of spinning process.
They are-
❶ Melt Spinning (It is used for polymers that can be melted easily.)
❷ Dry Spinning (It involves dissolving the polymer into a solution that can be evaporated.)
❸ Wet Spinning (It is used when the solvent can’t be evaporated and must be removed by chemical means.)

Melt Spinning:
Melt spinning uses heat to melt the polymer to a viscosity suitable for extrusion. This type of spinning is used for
polymers that are not decomposed or degraded by the temperatures necessary for extrusion. This method is used
by 70% of the fibers.

Spinning process:
❶ In melt spinning, polymer is heated and it melts to form a liquid spinning solution or dope.
❷ Chips of polymers are fed to a hopper which is heated. There is a grid (sieve) at the base which permits only
molten liquid to pass through.
❸ Then the solution is purified by filter.
❹ The molten polymer is extruded at high pressure and constant rate through a spinneret into a relatively cooler
air stream that solidifies the filaments.
❺ Finally the filament yarn either is immediately wound onto bobbins or is further treated for certain desired
characteristics or end use.
Example: Melt spinning is used for the production of polyester, nylon, olefin, saran and glass fibers.
Advantages:
►High speed (275 to 1500 yds/min); (4000 yds/min spin draw)
►No solvents
►No purification problems
Disadvantages:
►Separate drawing step (unless spin draw)

Dry spinning:
Dry spinning is used for polymers that need to be dissolved in a solvent. Solvent spinning (dry spinning and wet
spinning) are used by 30% of the fibers.

Spinning process:
❶ In dry spinning, a volatile solvent is used to dissolve the raw materials and form a salutation.
❷ Then the solution is purified by filter.
❸ The solution is extruded through a spinneret into a warm air chamber where the solvent evaporates, solidifying
the fine filaments.
❹ Finally the filament yarn either is immediately wound onto bobbins or is further treated for certain desired
characteristics or end use.
Example: Dry spinning is used in the production of acetate, triacetate, and some acrylic, modacrylic, spandex, and
vinyon (PVC,PVA) fibers.
Advantages:
►Yarn does not require purification
Disadvantages:
►Flammable solvent hazards
►Solvent recovery
►Slow (200-400 yds/min)

Wet Spinning:
This is the oldest, most complex and also the most expensive method of man-made yarn manufacture. This type of
spinning is applied to polymers which do not melt and dissolve only in non-volatile or thermal unstable solvents.

Spinning process:
❶ In wet spinning, a non-volatile solvent is used to convert the raw material into a solution.
❷ The solvent is extruded through the spinneret either by simply washing it out or by a chemical reaction between
the polymer solution and a reagent in the spinning bath.
❸ After extrusion, the solvent is removed in a liquid coagulation medium.
❹ Finally the filament yarn either is immediately wound onto bobbins or is further treated for certain desired
characteristics or end use.
Example: Wet spinning is used in the production of aramid, Lyocell, PVC, Vinyon (PVA), viscose rayon, spandex,
acrylic and modacrylic fibers.
Advantages:
►Large tows can be handled
Disadvantages:
►Slow (70-150 yds/min)
►Washing to remove impurities
►Solvent and chemical recovery
General process diagram of melt, dry and wet spinning process
Difference between Melt spinning, Dry spinning & Wet spinning

https://textilestudycenter.com/melt-spinning-dry-spinning-and-wet-spinning-method/