WHAT IS MELT-BLOWN EXTRUSION AND HOW IS IT USED FOR MAKING MASKS?

Covid-19 has popularized the use of face masks. The high-quality face masks available from top face mask manufacturers are considered both comfortable to use and effective. These masks (3 ply face mask or KN95/N95 Face Mask) are generally manufactured using the melt-blown extrusion process. In this one-step process high-velocity air is blown through the molten thermoplastic resin from the extruder dye tip onto a conveyor or takes up the screen to form a finely fibrous and self-bonding web. It helps to produce the non-woven fabric. This kind of fabric is created by bonding the material mechanically, thermally, or chemically. The following features make the fiber manufactured through melt-blown extrusion ideal for face masks. 

Melt Blown Fabric

• Absorbency- This melt-blown fabric is known for its absorbent, elasticity, and high filtration properties. It is quick to pick up oil and other unwanted objects. Hence the air you inhale through the fabric is devoid of air pollutants.
• Bacterial barrier- Due to its high absorption and filtering property, the face masks are also considered as great at preventing bacteria. Experts suggest that Covid-19 patients wear face masks. This will help to prevent the spread of coronavirus through cough and sneeze.
• Breathable- The best part, while the mouth and nose remain covered under this face mask, this kind of fiber is extremely breathable. This makes the masks manufactured using the melt-blown process ideal for long time wear.
• Cushioning- The melt-blown fiber is soft. So, when you wear the face masks, it acts as a soft cushion on your nose and mouth.
• Stretchable- The melt-blown fiber is stretchable. Melt-blown adds extra strength to the fiber. For this reason, face masks made with this high-quality fiber fit on any face.
• Washable- The melt-blown fabric is ideal for multiple washes. For this reason, it is used to manufacture face masks that can be washed after every use. This type of fiber is also great to manufacture a disposable 2 ply face mask.

The melt-blown fabric is also known for flame retardancy, liquid repellency, resilience, and sterile properties.

The key steps followed in the melt-blown extrusion process are

• Resin Feed System- The thermoplastic resin is the primary material used to manufacture the face masks. The first step is to store the material in the resin bag and is then fed into the extruder hopper.
• Extruder Assembly- In this step the pellets are received from the resin fed system.
• Metering Pump- The pump delivers a clean poly mix to the die assembly. It is also accountable for process variations in pressure, temperature, and viscosity of the molten polymer.
• Melt Blown Die Assembly- Under this step, the die assembly ensures that there is uniformity of the manufactured melt-blown fiber.
• Collector-The collector speed is changed to modify the density of the fiber. This step helps to modify the fiber density and make it usable for different applications.
• Winder Unit- In this step, the cooled fabric is wound on the cardboard. In this process, the fiber is strengthened. This makes the fiber apt for manufacturing medical and surgical masks.

While the process steps remain the same, the material, temperature, and the collector speed can be modified to manufacture customized melt-blown fabric. The multi-layer face masks are hence manufactured following the melt-blown process. We are face mask manufacturer, our mask manufacturing factory have capacity of half a million mask per day, to book bulk order please visit www.rhysley.org. We also sell face mask machines, full or semi-automatic 3 ply mask making machines & KN95/N95 mask making machines are available for sale.